Dodge Sprinter 2006 Manual page 1677

VA
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
DIAGNOSIS AND TESTING - INJECTOR
LEAK QUANTITY . . . . . . . . . . . . . . . . . . . . . . . 2
FU EL SY ST EM
WARN I N G
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO
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
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD PLACED IN THE SUSPECTED
AREA WHILE THE ENGINE IS NOT RUNNING.
START THE VEHICLE AND ALLOW THE ENGINE TO
RUN FOR A SHORT PERIOD. TURN THE ENGINE
OFF AND INSPECT THE PIECE OF CARDBOARD.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.
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
FUEL SYSTEM
TABLE OF CON T EN T S
page
THE INJECTORS. THIS
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM COMPONENTS . . . . . . . . . . . . 3
STANDARD PROCEDURES - DRAINING
WATER FROM FUEL FILTER . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - LOW
PRESSURE FUEL PUMP TEST . . . . . . . . . . . . 4
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 31
CIRCUIT. ALL CDI FUEL SYSTEM COMPONENTS
CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO
BE EXCHANGED AND THE LINES FLUSHED.
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO
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
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD PLACED IN THE SUSPECTED
AREA WHILE THE ENGINE IS NOT RUNNING.
START THE VEHICLE AND ALLOW THE ENGINE TO
RUN FOR A SHORT PERIOD. TURN THE ENGINE
OFF AND INSPECT THE PIECE OF CARDBOARD.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.
H igh -pr essu r e fu el lin e lea ks ca n ca u se st a r t in g
pr oblem s a n d poor en gin e per for m a n ce.
• Tu r n t h e en gin e off.
• P la ce a piece for ca r dboa r d in t h e su spect ed a r ea
(F ig. 1).
• St a r t t h e en gin e a n d a llow t o r u n for a sh or t
per iod.
• Tu r n t h e en gin e off.
• In spect t h e ca r dboa r d.
FUEL SYSTEM 14 - 1
page
THE INJECTORS. THIS