Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 415

REMOVAL - HIGH PRESSURE PUMP

(Refer to 14 - FUEL SYSTEM - WARNING)
(1) Disconnect negative battery cable.
(2) Remove viscous fan clutch (Refer to 7 - COOL-

ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).

(3) Unplug electrical connectors at high pressure

pump.

CAUTION: DO NOT slacken the threaded connec-
tion. Use a wrench to counterhold at the threaded
connection when loosening and tightening the
union nut. DO NOT EXCEED tightening torque.

CAUTION: DO NOT crimp or bend fuel line. Capture
all fluids that flow out of connections.

(4) Disconnect the high pressure line at high pres-

sure pump (Fig. 8).

(5) Detach fuel supply and return flow line at high

pressure pump using special tool #9539 (Fig. 8).

NOTE: Care must be taken not to drop the high
pressure pump drive when removing pump. Inspect
the pump drive for wear. If wear is present replace
the drive and gear.

(6) Remove bolts attaching high pressure pump

and remove pump (Fig. 8).

INSTALLATION - HIGH PRESSURE PUMP

(Refer to 14 - FUEL SYSTEM - WARNING)

CAUTION: Clean sealing surfaces with appropriate
solvents and replace all seals.

NOTE: Inspect then attach high pressure pump
drive if pump is being replaced. If wear is present at
drive, replace drive and gear.

(1) Position and secure the high pressure pump to

cylinder head (Fig. 9). Tighten bolts to 14 N·m (124
lbs. in.).

CAUTION: NEVER slacken the thread connection.
Use a wrench to counterhold at threaded connec-
tion when slackening and tightening torque in order
to avoid also slackening the threaded connection
the next time.

Fig. 8 HIGH PRESSURE FUEL PUMP

1 - INTERMEDIATE GEAR
2 - HIGH PRESSURE PUMP
3 - SEALING RING
4 - DRIVER
5 - HIGH PRESSURE LINE
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
8 - BOLTS
9 - FUEL QUANTITY CONTROL VALVE
10 - FUEL TEMPERATURE SENSOR

Fig. 9 HIGH PRESSURE FUEL PUMP

1 - INTERMEDIATE GEAR
2 - HIGH PRESSURE PUMP
3 - SEALING RING
4 - DRIVER
5 - HIGH PRESSURE LINE
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
8 - BOLTS
9 - FUEL QUANTITY CONTROL VALVE
10 - FUEL TEMPERATURE SENSOR

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FUEL DELIVERY

14 - 17

CAUTION: DO NOT crimp or bend fuel line. Inspect
sealing cone at line; replace line if compression
exists.

NOTE: Care must be taken not to cross the fuel
return and supply lines during installation.

(2) Attach fuel flow supply and return lines,

recrimping clamps using special tool #9539 (Fig. 9).

CAUTION: NEVER slacken the thread connection.
Use a wrench to counterhold at threaded connec-
tion when slackening and tightening torque in order
to avoid also slackening the threaded connection
the next time.

CAUTION: DO NOT crimp or bend fuel line. Inspect
sealing cone at line; replace line if compression
exists.

(3) Attach

high

pressure

fuel

line

to

pump.

Tighten to 22N·m (194 lbs.in.) (Fig. 9).

(4) Install the viscous fan.
(5) Connect negative battery cable.
(6) Start engine, allow to run, turn engine off and

inspect for leaks (Refer to 14 - FUEL SYSTEM -
WARNING), (Refer to 14 - FUEL SYSTEM - DIAG-
NOSIS AND TESTING).

FUEL PUMP MODULE

DESCRIPTION

The fuel pump module is installed in the top of the

fuel tank (Fig. 10). The pump module contains the
following components:

• Electric fuel pump (transfer, or lift pump)

• Fuel reservoir

• Fuel gauge sending unit (fuel level sensor)

• Fuel supply line connection

• Fuel return line connection

Fuel is supplied to the high-pressure fuel injection

pump by the low-pressure fuel transfer (lift) pump.
This electric fuel pump is attached to the fuel pump
module and supplies approximately 165 liters/hour
(43.6 gallons/hour). A low-pressure fuel pump is not
attached to the engine.

REMOVAL

CAUTION: To prevent damage to the float rod, the
float and float rod must be removed from the pump
module. This step must be done before the pump
module is removed from the fuel tank.

(1) Drain and remove fuel tank. Refer to Fuel

Tank Removal/Installation.

(2) Thoroughly clean area around pump module at

top of tank.

(3) Disconnect all fuel lines from pump module fit-

tings.

(4) The plastic fuel pump module locknut (lock-

ring) is threaded onto fuel tank. Install Special Tool
#6856 to locknut and remove locknut (Fig. 11). The
fuel pump module will spring up slightly after lock-
nut is removed.

Fig. 10 TOP OF FUEL TANK

1 - Cooler Lines
2 - Top of Tank
3 - Expansion Tank
4 - Check Valves
5 - Check Valve
6 - Module Lock Ring
7 - Fuel Pump Module

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FUEL DELIVERY

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(5) Pull module assembly up just a few inches to

gain access to float support arm/rod (3) (Fig. 12). Be
careful not to bend float support rod while removing
pump module.

(6) Rotate clip (2) (Fig. 13) to release float rod (3)

from fuel level sensor (1).

(7) Twist rod (3) slightly (Fig. 14) to remove from

fuel level sensor. Do not allow float assembly to fall
into fuel tank.

(8) While holding float rod, remove fuel pump

module from fuel tank.

(9) Remove float assembly from fuel tank.
(10) Remove and discard rubber gasket (seal) from

pump module.

Fig. 11 FUEL PUMP MODULE R/I

1 - LOCKNUT (LOCKRING)
2 - SPECIAL TOOL #6856
3 - TOP OF PUMP MODULE

Fig. 12 FLOAT ROD CLIP

1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD

Fig. 13 FLOAT ROD CLIP REMOVAL

1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD

Fig. 14 FLOAT ROD CLIP REMOVED

1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD

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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

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FUEL DELIVERY

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