coolant MERCEDES-BENZ SPRINTER 2006 Service Manual

(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 49)
(7) Remove the engine support fixture and adap-
tors.
RIGHT MOUNT
REMOVAL
(1) Install engine support fixture #8534 with adap-
tors #8534-16 and raise the engine slightly.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 50)
(4) Lower the vehicle.
(5) Using the engine support fixture, raise the
engine until the weight is no longer on the mounts.
(6) Raise and support the vehicle.
(7) Remove the engine mount nuts and remove the
mount (Fig. 50)
INSTALLATION
(1) Position the engine mount into the stop plate
(Fig. 50)
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N´m (33 lbs. ft.) (Fig.
50)
(3) Lower the vehicle.
(4) Lower the engine on to the engine mounts until
they contact (Fig. 50)(5) Hand tighten the engine support to engine
mount bolt (Fig. 50).
(6) Lower the engine on to the engine mount and
tighten bolt to 83 N´m (61 lbs.ft.) (Fig. 50)
(7) Remove the engine support fixture and adap-
tors.
OIL
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.
INSTALLATION - OIL SEPARATOR
(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N´m (70
lbs. in.).
(4) Connect breather hose.
OIL COOLER & LINES
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194ÉF (90ÉC). WEAR PRO-
TECTIVE CLOTHING AND EYE WEAR. RISK OF
POISONING IF COOLANT IS SWALLOWED. STORE
COOLANT IN PROPER AND APPROPRIATELY
MARKED CONTAINERS.
(1) Partailly drain cooling system.
(2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
(Fig. 51).
(4) Remove the oil cooler from the timing case
cover (Fig. 51).
Fig. 50 RIGHT ENGINE MOUNT
1 - NUT
2 - WASHER
3 - STOP PLATE
4 - ENGINE MOUNT
5 - ENGINE SUPPORT
6 - WASHER
7 - BOLT
9 - 56 ENGINEVA

INSTALLATION
(1) Clean all sealing surfaces.
(2) Install the engine oil cooler to the timing case
cover with a new gasket. Tighten bolts to 14N´m (124
lbs. in.) (Fig. 51).
(3) Reconnect the coolant hoses and tighten
clamps.
(4) Install new oil filter and tighten oil filter cap to
25N´m ( 18 lbs. ft.) (Fig. 51).
(5) Refill cooling system.
(6) Start engine and inspect for leaks.
(7) Turn engine off and check engine oil level. Add
as necessary.
OIL FILTER
REMOVAL
(1) Unscrew the oil filter cap (Fig. 52)
(2) Remove clean and inspect cap gasket, replace
as necessary.
(3) Remove oil filter (Fig. 52).
INSTALLATION
(1) Inspect oil filter cap gasket, if all right, lubri-
cate with clean engine oil.
(2) Install oil filter.
(3) Screw oil filter cap to housing and tighten to
25N´m (18 lbs. ft.) (Fig. 52). Adjust oil level as neces-
sary.
OIL JET
DESCRIPTION
There are five oil jets installed in the engine block
(Fig. 53). These oil jets are used to cool and lubricate
the piston assemblies.
Fig. 51 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
Fig. 52 ENGINE OIL COOLER
1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER
VAENGINE 9 - 57

REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Drain engine oil into a suitable, and appropri-
ately marked container.
(4) Remove engine mount to chassis nuts.
(5) Lower vehicle and install engine support.
(6) Remove the turbo charger heat shield to radia-
tor support bolts.
(7) Raise engine until the weight of the engine no
longer rests on the engine mounts.
(8) Raise and support the vehicle.
(9) Detach the front stabilizer bar at the front axle
and rotate it downward.
(10) Unplug the oil level sensor (Fig. 67).
(11) Remove the oil level sensor retaining screw,
oil level sensor and discard the O-ring (Fig. 67).
INSTALLATION
(1) Seat new O-ring on oil level sensor and lubri-
cate O-ring with clean engine oil (Fig. 67).
(2) Install the oil level sensor into the oil pan and
tighten screw to 124 lbs. in.(14N´m) (Fig. 67).
(3) Connect oil level sensor wiring harness connec-
tor (Fig. 67).
(4) Rotate front stabilizer bar upward and secure
to axle beam. Tighten to 22 lbs.ft. (30 N´m)
(5) Lower the vehicle.
(6) Lower the engine into the mounts.
(7) Remove engine support fixture.(8) Raise and support the vehicle.
(9) Tighten both engine mount to chassis nuts.
(10) Install and tighten oil drain plug.
(11) Lower vehicle and install the appropriate
engine oil.
INTAKE MANIFOLD
REMOVAL
WARNING: NO FIRE, SPARKS OR SMOKING.
STORE FUELS ONLY INTO SUITABLE AND APPRO-
PRIATELY MARKED CONTAINERS, AND WEAR
PROTECTIVE CLOTHING. (Refer to 14 - FUEL SYS-
TEM - WARNING).
WARNING: DO NOT OPEN THE COOLING SYSTEM
UNLESS THE COOLANT TEMPERATURE IS BELOW
90ÉC (194ÉF). OPEN RADIATOR CAP SLOWLY TO
RELEASE PRESSURE. STORE COOLANT ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS, WEAR PROTECTIVE CLOTHING AND
EYE PROTECTION.
(1) Disconnect the negative battery cable.
(2) Partially drain coolant from the radiator.
(3) Remove the engine cover (Refer to 9 - ENGINE
- REMOVAL).
(4) Remove the high pressure fuel lines (Fig. 68).
Fig. 67 OIL LEVEL SENSOR
1 - OIL PAN
2 - O-RING
3 - WIRING HARNESS
4 - BOLT
5 - OIL LEVEL SENSOR
VAENGINE 9 - 65

(8) Disconnect the EGR wiring harness connector
(Fig. 69).
(9) Remove the bolt retaining the engine wiring
harness to the intake manifold.
(10) Disconnect the coolant hose at the EGR valve.
NOTE: Collect and store any fluid spillage when
disconnecting components.
(11) Disconnect both fuel lines at the fuel filter
(Fig. 69).
(12) Remove the lower intake manifold support
bracket (Fig. 70).
(13) Raise and support the vehicle.
(14) Remove the rear intake manifold mounting
bolts while accessible from below.
(15) Lower the vehicle.
Fig. 69 INTAKE MANIFOLD
1 - CLIP 6 - ENGINE OIL COOLER
2 - INTAKE MANIFOLD 7 - HIGH PRESSURE FUEL RAIL
3 - EGR VALVE 8 - COOLANT TEMPERATURE SENSOR
4 - EGR VALVE COOLANT HOSE 9 - FUEL RAIL PRESSURE SENSOR
5 - FUEL FILTER 10 - CHARGE AIR HOSE
VAENGINE 9 - 67

NOTE: Access to one of the intake manifold bolts is
through a supplied hole in the manifold.
(16) Remove the remaining intake manifold bolts,
lift the intake manifold up and out while guiding the
engine wiring harness and fuel lines through the
openings in the intake manifold, then remove the
gasket (Fig. 70).
NOTE: Install the EGR valve with new gasket onto
the new intake manifold if the intake manifold is
being replaced.
INSTALLATION
NOTE: If the intake manifold is being replaced,
install the EGR valve with new gasket.
(1) Clean both mating surfaces and install a new
intake manifold gasket with the intake manifold.
Guide the engine wiring harness and fuel lines
through the intake manifold openings. Tighten man-
ifold bolts to 16 N´m (142 lbs. in.) in a cross direc-
tional pattern beginning with the middle bolts and
tightening outward to the ends.
(2) Raise and support the vehicle.
(3) Install the rear intake manifold bolts and
tighten to 16 N´m (142 lbs. in.) (Fig. 70).
(4) Install the lower intake manifold support
bracket. Tighten bolts to 20 N´m (177 lbs. in.) (Fig.
70).
(5) Lower the vehicle.(6) Connect both fuel lines to fuel filter assembly
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL FILTER - INSTALLATION).
(7) Connect the coolant hose at the EGR valve
(Fig. 69).
(8) Secure the engine wiring harness and cable
duct to the intake manifold. tighten fastener to 9N´m
(80 in. lbs.).
(9) Connect the EGR wiring harness connector
(Fig. 69).
(10) Connect the fuel pressure sensor electrical
connector
(11) Install the fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - INSTALLA-
TION).
NOTE: The high pressure fuel lines must be counter
held when tightening to prevent damage.
(12) Install the high pressure fuel lines (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- INSTALLATION).
(13) Connect the charge air hose to the intake
manifold (Fig. 69).
(14) Install the engine cover (Refer to 9 - ENGINE
- INSTALLATION).
(15) Fill the cooling system.
(16) Connect the negative battery cable.
(17) Start the engine, run until warm, turn engine
off and inspect for leaks. Care must be taken to
observe the fuel system warning. (Refer to 14 - FUEL
SYSTEM - WARNING).
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the exhaust heat shield.
(3) Raise and support the vehicle.
(4) Remove the turbocharger support bracket.
(5) Loosen the exhaust pipe to engine bracket fas-
teners at the rear of the engine block.
(6) Remove the exhaust hanger fasteners at the
muffler.
(7) Disconnect the front exhaust pipe to turbo-
charger fastener (Fig. 71).
Fig. 70 INTAKE MANIFOLD
1 - INTAKE BOLT ACCESS HOLE
2 - INTAKE MANIFOLD
3 - SUPPORT BRACKET
9 - 68 ENGINEVA

(8) Install the exhaust hanger fasteners at the
muffler.
(9) Tighten the exhaust hanger bracket to engine
block.
(10) Install the turbocharger support bracket.
(11) Lower the vehicle.
(12) Install the air cleaner duct to the turbo-
charger (Fig. 71).
(13) Install the exhaust heat shield.
(14) Connect the negative battery cable.
TIMING CHAIN COVER
REMOVAL
WARNING: DO NOT OPEN COOLING SYSTEM
UNLESS TEMPERATURE IS BELOW 90ÉC (194ÉF).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE COOLANT IN APPROVED CONTAINER
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING COOLANT. WEAR PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
(2) Position piston of cylinder 1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Install retaining lock for crankshaft/starter
ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).
(5) Drain engine oil.
(6) Remove the oil filter to allow the oil to flow off
into the oil pan.
(7) Remove the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).
(8) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(9) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove accessory drive belt.
(11) Remove the high pressure fuel pump (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).
(12) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(13) Remove accessory drive belt pulley and vibra-
tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - REMOVAL).
(14) Remove the power steering pump.NOTE: NO NOT open the air conditioning system.
(15) Unplug AC compressor electrical connector
and unbolt AC compressor. Relocate in lower engine
compartmentwith outopening the system.
(16) Remove the generator with wiring attached
and relocate somewhere in the engine compartment.
(17) Install engine support fixture.
(18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat
exchanger at crankcase (Fig. 73).
(20) Remove the cylinder head to timing cover
bolts (Fig. 73).
(21) Remove the timing cover bolts and cover (Fig.
73).
(22) Remove remaining ancillary components
attached to the timing case cover (Fig. 73).
NOTE: Inspect condition of hoses and clamps,
replace as necessary.
(23) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(24) Remove timing case cover (Fig. 73).
Fig. 73 TIMING CHAIN COVER
1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER
9 - 70 ENGINEVA

INSTALLATION
CAUTION: Care must be taken to closley inspect
the gasket area around the time case cover to cyl-
inder head gasket coolant port. If damage is found,
replace the cylinder head gasket. Failure to do so
may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.
(1) Inspect cylinder head gasket and oil pan gas-
ket. If damaged, replace.
(2) Replace the front crankshaft seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(3) Install ancillary components to timing case
cover.
(4) Apply sealant to the marked surfaces with a
bead thickness of 1.5   0.5 mm (Fig. 74).
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position and install timing case cover. Tighten
bolts to 20 N´m (177 lbs in) (Fig. 73).(6) Install the M8 bolts of cylinder head on timing
case cover. Tighten bolts to 20 N´m (177 lbs in) (Fig.
73).
(7) Install timing chain tensioner with new seal
(Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&PULLEY - INSTALLATION).
(8) Position and install the oil pan. Tighten M6
bolts to 9 N´m (80 lbs in) and M8 bolts to 20 N´m
(177 lbs in).
(9) Install belt /pulley vibration damper. Tighten
M8.8 bolt in two stages, 200N´m (147 lbs ft.) then
90É, M10.9 bolt 325N´m (240 lbs ft) then 90É.
(10) Remove the engine support fixture.
(11) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(12) Install the air conditioning compressor.
(13) Install the power steering pump.
(14) Install water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - INSTALLATION).
(15) Connect coolant hose to oil-water heat
exchanger.
(16) Install high pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -
INSTALLATION).
(17) Apply sealant to lower portion of, and install,
front cover to cylinder block. Tighten bolts to 20N´m
(177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD
- INSTALLATION).
(18) Remove retaining lock for crankshaft/starter
ring gear.
(19) Tighten the oil drain plug to 30N´m (265 lbs
in).
(20) Install a new oil filter. tighten screw cap for
filter to 25N´m (221 lbs. in.).
(21) Install the accessory drive belt.
(22) Install the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).
(23) Install air intake hose.
(24) Fill coolant to the proper level, with the
proper coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(25) Fill the crankcase with the correct oil, to the
proper level. Refer to owners manual for specifica-
tions.
(26) Connect the negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
CAUTION: DO NOT pressure test cooling system
until the engine reaches operating temperature.
Fig. 74 TIMING CHAIN COVER SEALING SURFACE
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
VAENGINE 9 - 71

OPERATION
There are several modes of operation for the Com-
mon Rail Diesel Injection System.
Pre-injection The purpose of the pre-injection func-
tion is to reduce noise and pollutants. The coolant
temperature, charge air temperature and atmo-
spheric pressure are use to correct the quantity of
pilot injection. The quantity of pilot injection now
determined is deducted from the quantity of main
injection in order to establish whether sufficient
quantity is available for the following main injection.
The rail pressure is chosen sufficiently high so that
a minimum quantity is injected. If the quantity of
main injection is too small the pilot injection is
switched off by the ECM.
The start of actuation of pilot injection is calcu-
lated dependent on operating point, the following
data being taken into account:
Shutting Off Pre-injection The pre-injection is shut
off when:
²The moment of pre-injection is exceeded
²Engine speed too high
²Pre-injected quantity too low
²Main injected quantity too low²Insufficient fuel rail pressure
²Engine is switched off
Calculating Pre-injection Quantity The pre-injec-
tion quantity is calculated on the basis of:
²Engine speed
²Atmospheric pressure
²Coolant temperature
²Boost air temperature
²Fuel rail pressure
Main Injection The purpose of main injection func-
tion is to enable the injection time and injection
period calculated by the ECM. The injection quantity
required by the engine is divided into the per-injec-
tion and main injection quantity. If the main injec-
tion quantity computed by the ECM is too small, no
pre-injection takes place.
Start of Actuation
The start of actuation of main injection is depen-
dent on engine speed and quantity. In addition, it is
corrected depending on the following values:
²Coolant temperature
²Boost air temperature
²Atmospheric pressure
²Pre-injection corrected YES/NO
Fig. 1 FUEL SUPPLY
1 - HIGH PRESSURE FUEL PUMP 8 - FUEL INJECTOR
2 - FUEL FROM LOW PRESSURE PUMP 9 - HIGH PRESSURE FUEL FROM HIGH PRESSURE PUMP
3 - FUEL FILTER 10 - FUEL PRESSURE SOLENOID
4 - LOW PRESSURE FUEL PUMP 11- FUEL RAIL
5 - FUEL TANK 12 - FUEL RAIL PRESSURE SENSOR
6 - RETURN FUEL 13 - FUEL QUANTITY CONTROL VALVE
7 - HIGH PRESSURE FUEL FROM HIGH PRESSURE PUMP 14 - FUEL TEMPERATURE VALVE
VAFUEL DELIVERY 14 - 7

Switching Off Main Injection
Main injection is switched off when:
²Engine speed is too high >4700 - 4800 rpm
²Main injection quantity too low
²Low fuel pressure in fuel rail
²Engine off
²External quantity control
²Deceleration mode
Calculating Main Injection
The quantity of main injection is calculated by:
²Engine speed
²Atmospheric pressure
²Coolant temperature
²Boost air temperature
²Fuel rail pressure
²Boost pressure
Period of Actuation
For calculating the period of actuation of the main
injection it is necessary to know whether a pre-injec-
tion has occurred or not.
The coolant temperature, charge air temperature
and the atmospheric pressure are used for correcting
the main injection quantity. If main injection quan-
tity is less than a minimum quantity which is depen-
dent on fuel rail pressure, no preinjection takes
place. In this case, only main injection is performed.
If the quantity is then still below the minimum
quantity, neither main injection or pre-injection takes
place (deceleration mode).
Deceleration Mode
The purpose of the deceleration mode is to inter-
rupt the operation of the injectors. The ECM deter-
mines the accelerator pedal position from a supplied
signal and it determines the engine speed by the
crank sensor. In the overrun and with the engine
speed above 1600, with the accelerator pedal no
pressed, the injectors are no longer actuated and the
fuel rail pressure is lowered by the pressure regula-
tor valve.
Full Load Injected Quantity
The purpose of the full load injected quantity is to
minimize the formation of smoke. The ECM limits
the fuel rail pressure when the engine is operating at
full load by way of the quantity control valve, and
quantity of fuel injected by the injectors. this mini-
mizes the formation of smoke when accelerating and
driving at constant speeds. If a fault occurs at the
boost pressure control, full load injected quantity is
reduced.
Limiting Maximum Engine Speed
The ECM determines the engine speed based on
the signal supplied by the crankshaft sensor and lim-its this by interrupting the operation of the fuel
injectors.
Fuel Quantity Control
The fuel quantity is controlled separately for each
cylinder by the ECM inline with the firing order.The
ECM detects the operating state which exists at the
engine by means of the sensors. In order adapt the
quantity injected, either the fuel rail pressure can be
adjusted by the fuel solenoid and quantity control
valve or the actuation time of the solenoid valves in
the injectors
Boiling Protection
In order to protect against thermal overload and
along with criteria programmed in the ECM, the
injection quantity is reduced as a function of the cool-
ant temperature and vehicle speed. If the coolant
temperature sensor fails the oil temperature signal
from the oil sensor is used as a suitable value.
Fuel Tank Protection
The fuel rail pressure is lowered in order to protect
the fuel tank from overheating. The fuel temperature
sensor measures the temperature of the fuel being
supplied from the tank, in the high pressure flange.
If the fuel is too warm the fuel rail pressure is fur-
ther reduced by the quantity control valve.
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING FUEL
TANK - DIESEL
(1) Position a drain hose into the fuel fill opening.
(2) Drain fuel tank using an approved diesel fuel
draining station.
FUEL CONTAMINATION
If a diesel engine's fuel supply has been contami-
nated with gasoline, the following procedure must be
followed:
(1) Remove all fuel from the fuel tank. (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE-DRAINING FUEL TANK) Use an
appropriate fuel container. Dispose of the contami-
nated fuel using the proper procedures.
CAUTION: Dispose of petroleum based products in
a manner consistent with all applicable Local, State,
Federal, and Provincial regulations.
(2) Remove and clean fuel tank. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL TANK -
REMOVAL)
(3) Install the fuel tank. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL TANK - INSTALLA-
TION)
14 - 8 FUEL DELIVERYVA

INSTALLATION - 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) Loosen the fuel rail mounting bolts to install
lines free of stress.
CAUTION: Inspect sealing cone at lines. Replace if
compression points exist. Ensure lines are exactly
located.
(2) Position and install fuel lines (Fig. 3). Tighten
to 22N´m (195 lbs. in.) using a wrench to counterhold
at threaded connection.
(3) Tighten fuel rail to 14N´m (124 lbs. in.).
(4) 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.(5) Start engine, run for a few minutes, turn
engine off and inspect for leaks (Refer to 14 - FUEL
SYSTEM - WARNING), (Refer to 14 - FUEL SYS-
TEM - DIAGNOSIS AND TESTING).
FUEL RAIL PRESSURE SEN-
SOR
DESCRIPTION
The fuel rail pressure sensor is attached to the
front of the fuel rail. The sensor supplies the current
fuel rail pressure to the ECM.
OPERATION
Non-constant fuel system pressure influences the
position of a diaphragm inside the sensor. This
results in a variation in the electrical resistance. The
fuel rail pressure sensor supplies the appropriate
voltage signal to the ECM.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the sensor wiring harness connector
(Fig. 4).
NOTE: Place a shop towel underneath the sensor to
capture any fuel spillage.
(3) Unscrew the sensor and discard the seal.
Fig. 3 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
Fig. 4 FUEL RAIL PRESSURE SENSOR
1 - FUEL RAIL PRESSURE SENSOR
2 - FUEL RAIL
3 - COOLANT TEMPERATURE SENSOR
14 - 12 FUEL DELIVERYVA