Dodge Sprinter 2006 Manual page 1679

VA
Fig. 2 Special Tool # 9545
1 - SPECIAL TOOL #9545
(7) Con n ect a sca n t ool, select fr om Ma in Men u ,
Syst em Select , E n gin e, Syst em Test s, F u el Qu a n t it y
Test , E n gin e Cr a n kin g Test a n d follow t h e scr een .
(8) Aft er t en secon ds, a m a xim u m of 2.5 m l
(bet ween 2 & 3 gr a du a t ion lin es) m a y be r ea ch ed in
t h e in n er via ls. If t h e level h a s exceeded t h e 2.5 m l,
r epla ce t h a t a ffect ed cylin der 's in ject or, clea r t h e
m em or y u sin g t h e sca n t ool, em pt y t h e t est via ls, a n d
r et est .
RUNNING 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. Engine temperature must be above 80° C
(176°F) to perform the running test.
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. Th is t est will a ssist in det er m in in g a defec-
t ive or in t er n a lly lea kin g in ject 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) 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).
(6) Con n ect a sca n t ool, select fr om Ma in Men u ,
Syst em Select , E n gin e, Syst em Test s, F u el Qu a n t it y
Test , E n gin e Ru n n in g Test a n d follow t h e scr een .
(7) Aft er t en secon ds, a m a xim u m of five gr a du a -
t ion lin es (40 m l) of t h e la r ge t est via l m a y be
r ea ch ed. If t h e level h a s exceeded t h e five gr a du a t ion
lin e, r epla ce t h a t a ffect ed cylin der 's in ject or, clea r t h e
m em or y u sin g t h e sca n t ool, em pt y t h e t est via ls, a n d
r et est .
STAN DARD PROCEDU RE
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM COMPONENTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines, fuel rail, and fuel injection
pump. Very tight tolerances are used with these
parts. Dirt contamination could cause rapid part
wear and possible plugging of fuel injector nozzle
tip holes. This in turn could lead to possible engine
misfire. Always wash/clean any fuel system compo-
nent thoroughly before disassembly and then air
dry. DO NOT wire brush injector nozzles when
cleaning. Cap or cover any open part after disas-
sembly. Before assembly, examine each part for
dirt, grease or other contaminants and clean if nec-
essary. When installing new parts, lubricate them
with clean engine oil or clean diesel fuel only.
STANDARD PROCEDURES - DRAINING WA TER
FROM FUEL FILTER
Con n ect a h ose t o t h e Wa t er in F u el (WIF ) dr a in
a n d pla ce it in a clea r ly m a r ked a n d su it a ble con -
t a in er. Open t h e WIF dr a in by t u r n in g cou n t er clock-
wise (F ig. 3). Tu r n t h e ign it ion key on for 20 secon ds
(Refer t o low pr essu r e fu el pu m p oper a t ion ). Repea t
t h e pr ocedu r e u n t il a ll wa t er is r em oved, close t h e
dr a in a n d r em ove t h e h ose.
FUEL SYSTEM 14 - 3