Fuel System - DaimlerChrysler SPRINTER2006 Service Manual

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
FUEL SYSTEM
WARNING
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 CONTENTS
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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.
DIAGNOSIS AND TESTING
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.
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
• Turn the engine off.
• Place a piece for cardboard in the suspected area
(Fig. 1).
• Start the engine and allow to run for a short
period.
• Turn the engine off.
• Inspect the cardboard.
FUEL SYSTEM 14 - 1
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THE INJECTORS. THIS