Dodge Sprinter 2006 Manual page 1678

14 - 2 FUEL SYSTEM
If a h igh -pr essu r e lin e con n ect ion is lea kin g, cou n -
t er h old a n d t igh t en t h e con n ect ion t o specifica t ion
t h en per for m t h is pr ocedu r e a ga in (Refer t o 14 -
F UE L SYSTE M -
Repla ce a n y da m a ged, r est r ict ed or lea kin g h igh -
pr essu r e fu el lin es wit h t h e cor r ect r epla cem en t
lin e.
Fig. 1 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
DIAGNOSIS AND TESTING - AIR IN FUEL SYS-
TEM
Air will en t er t h e fu el syst em wh en ever fu el su pply
lin es, sepa r a t or filt er s, in ject ion pu m p, h igh -pr essu r e
lin es or in ject or s a r e r em oved or discon n ect ed. Air
t r a pped in t h e fu el syst em ca n r esu lt in h a r d st a r t -
in g, a r ou gh r u n n in g en gin e, en gin e m isfir e, low
power, excessive sm oke a n d fu el kn ock.
In spect t h e fu el syst em fr om t h e fu el t a n k t o t h e
in ject or s for loose con n ect ion s (Refer t o 14 - F UE L
SYSTE M - WARNING). Lea kin g fu el is a n in dica t or
of loose con n ect ion s or defect ive sea ls. Air ca n a lso
en t er t h e fu el syst em bet ween t h e fu el t a n k a n d t h e
fu el pu m p. In spect t h e fu el t a n k m odu le a n d fu el
lin es for da m a ge t h a t m igh t a llow a ir in t o t h e sys-
t em .
STANDARD P ROCE DURE ).
Wit h t h e DRBIII con n ect ed t o t h e veh icle, select
E n gin e a n d t h e select Sen sor Displa y. P a ge down t o
view F u el P r essu r e Set P oin t a n d Act u a l F u el P r es-
su r e. St a r t t h e en gin e a n d obser ve t h e F u el P r essu r e
Set P oin t a n d t h e Act u a l F u el P r essu r e. If t h e Act u a l
F u el P r essu r e Oscilla t es a bove a n d below t h e F u el
P r essu r e Set P oin t in a r egu la r cycle, in spect t h e fu el
syst em for a ir in t r u sion .
If t h e Act u a l F u el P r essu r e gr a du a lly dr ops below
t h e F u el P r essu r e Set P oin t t h en spikes well a bove
t h e F u el P r essu r e Set P oin t , r epla ce t h e fu el pr es-
su r e solen iod (Refer t o 14 - F UE L SYSTE M/F UE L
INJ E CTION/F UE L
RE MOVAL), a n d r ech eck.
DIAGNOSIS AND TESTING - INJECTOR LEAK
QUANTITY
WARNING: REVIEW THE HIGH PRESSURE FUEL
SYSTEM WARNING BEFORE BEGINNING SERVICE
(Refer to 14 - FUEL SYSTEM - WARNING).
CRANKING TEST
NOTE: If an injector is found to be out of specifica-
tion, repeat this test procedure after the injector
replacement. Hydraulic flow will take the path of
least resistance and multiple failures may be identi-
fied.
P er for m t h is t est wit h t h e en gin e a t oper a t in g t em -
per a t u r e, wh en possible. Th is t est will a ssist in
det er m in in g a defect ive or in t er n a lly lea kin g in jec-
t or (s) is pr esen t by m ea su r in g t h e a m ou n t of fu el
r et u r n .
(1) Tu r n t h e ign it ion off.
(2) Rem ove t h e en gin e cover (Refer t o 9 - E NGINE
- RE MOVAL).
(3) Discon n ect t h e fu el r et u r n h oses a t t h e t op of
t h e in ject or s.
(4) P in ch off t h e fu el r et u r n lin e a t t h e ba n jo bolt
fit t in g of t h e fu el r a il.
(5) Discon n ect t h e fu el r a il solen oid a n d ca m sh a ft
posit ion sen sor.
(6) In st a ll t h e t est via ls on t o t h e in ject or s a n d
secu r e wit h t h e r et u r n h ose clips (F ig. 2).
P RE SSURE SOLE NOID
VA
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