MERCEDES-BENZ SPRINTER 2006 Service Manual

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

(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

Fig. 20 FUEL TANK ASSEMBLY
1 - Strap Bolts (2)
2 - Hose (not with all engines)
3 - Fuel Outlet Line
4 - Fuel Return Line
5 - Plug
6 - Fuel Tank
7 - Tank Straps (2)8 - Nuts (2)
9 - Filler Tube
10 - Vent Hose
11 - Hose
12 - Clamps
13 - Cushioning Material
14 - Two-Way Valve
Fig. 21 FUEL COOLER LINES
1 - Expansion Tank
2-TopofTank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps
14 - 24 FUEL DELIVERYVA

REMOVAL
(1) Drain diesel fuel from tank. Refer to Standard
Procedure Ð Draining Fuel Tank Ð Diesel.
(2) Disconnect fuel fill and vent lines from body.
(3) Raise and support vehicle.
(4) Support tank with a hydraulic jack.
(5) Remove 2 fuel tank strap nuts (8) (Fig. 23) and
position straps (7) towards left side of vehicle.
(6) Carefully lower tank a few inches and discon-
nect electrical connector at top of fuel pump module.
(7) Disconnect fuel supply line at tank.
(8) Disconnect fuel return line at tank.
(9) Continue to carefully lower tank for removal.
(10) If fuel pump module is to be removed, thor-
oughly clean area at top of fuel pump around module.
(11) If fuel tank is to be replaced, remove fuel
pump module from tank. Refer to Fuel Pump Module
Removal/Installation procedures.
(12) If fuel cooler lines (Fig. 24) are to be removed,
use special pliers #9539 (Fig. 25).
Fig. 22 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
VAFUEL DELIVERY 14 - 25

INSTALLATION
(1) If fuel cooler lines (Fig. 27) are to be installed,
use special pliers #9539 (Fig. 28).
(2) If fuel tank is to be replaced, install fuel pump
module into tank. Refer to Fuel Pump Module
Removal/Installation procedures.
(3) Position fuel tank to hydraulic jack.
(4) Raise tank until positioned near body.
Fig. 23 FUEL TANK ASSEMBLY
1 - Strap Bolts (2)
2 - Hose (not with all engines)
3 - Fuel Outlet Line
4 - Fuel Return Line
5 - Plug
6 - Fuel Tank
7 - Tank Straps (2)8 - Nuts (2)
9 - Filler Tube
10 - Vent Hose
11 - Hose
12 - Clamps
13 - Cushioning Material
14 - Two-Way Valve
Fig. 24 FUEL COOLER LINES
1 - Expansion Tank
2-TopofTank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps
Fig. 25 FUEL LINE PLIERS-9539
14 - 26 FUEL DELIVERYVA

(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

FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module (Fig.
29). The sending unit consists of a float, an arm, and
Fig. 26 FUEL TANK ASSEMBLY
1 - Strap Bolts (2)
2 - Hose (not with all engines)
3 - Fuel Outlet Line
4 - Fuel Return Line
5 - Plug
6 - Fuel Tank
7 - Tank Straps (2)8 - Nuts (2)
9 - Filler Tube
10 - Vent Hose
11 - Hose
12 - Clamps
13 - Cushioning Material
14 - Two-Way Valve
Fig. 27 FUEL COOLER LINES
1 - Expansion Tank
2-TopofTank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps
Fig. 28 FUEL LINE PLIERS-9539
14 - 28 FUEL DELIVERYVA

a variable resistor track (card).
REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the fuel pump
module (4) (Fig. 30).
(1) Remove fuel pump module from fuel tank.
Refer to Fuel Pump Module Removal/Installation.
(2) Unplug sensor's 2±wire harness from pump
module electrical connector.
(3) Before disconnecting wiring from 2±wire har-
ness electrical connector, note position of each wire in
the connector. Record this position.
(4) Disconnect wiring from 2±wire harness electri-
cal connector using a terminal pick / removal tool.
Refer to Special Tools in 8W, Wiring for tool part
numbers.
(5) To remove sending unit from pump module,
press on plastic locking tabs (1) (Fig. 30) while slid-
ing sending unit (4) on its tracks.
INSTALLATION
(1) Noting their previous positions, connect wires
from 2±wire harness into its connector.
(2) Plug 2±wire harness connector into pump mod-
ule electrical connector.
(3) Position sending unit (4) (Fig. 31) to tracks on
fuel pump module. Slide and snap into place.
(4) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
Fig. 29 FUEL LEVEL SENSOR
1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT
Fig. 30 FUEL LEVEL SENSOR
1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT
Fig. 31 FUEL LEVEL SENSOR
1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT
VAFUEL DELIVERY 14 - 29