Sprinter 2005-2007

High Pressure Fuel Pump Drive Gear

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Removal & Installation



2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove viscous fan clutch. For additional information, refer to the following section, "Engine Fan, Removal & Installation.-
  4.  
  5. Unplug the electrical connectors at high pressure pump.
  6.  
  7. Disconnect the high pressure line at high pressure pump.
  8.  
  9. Detach the fuel supply and return flow lines at the high pressure pump using Special Tool 9539.
  10.  
  11. Remove bolts attaching high pressure pump and remove pump.
    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.

  12.  

To install:

  1. Position and secure the high pressure pump to cylinder head and tighten bolts to 10 ft. lbs. (14 Nm).
  2.  
  3. Attach the fuel flow supply and return lines, and crimp the clamps using Special Tool 9539.
    CAUTION
    NEVER slacken the thread connection. Use a wrench to counterhold at threaded connection 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.


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


    CAUTION
    NEVER slacken the thread connection. Use a wrench to counterhold at threaded connection 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.

  4.  
  5. Attach the high pressure fuel line to pump and tighten to 16 ft. lbs. (22Nm).
  6.  
  7. Install the viscous fan.
  8.  
  9. Connect negative battery cable.
  10.  
  11. Start the engine and check for leaks.
  12.  

3.0L Engine

WARNING
High pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 psi (1600 bar). 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. Wear safety goggles and adequate protective clothing when servicing fuel system.

  1. Remove the engine cover.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Release the fuel pressure.
  6.  
  7. Remove the high pressure line support bracket.
  8.  
  9. Remove the high pressure line retaining nut.
  10.  
  11. Remove the return line clamp using Fuel Line Pliers 9539.
  12.  
  13. Remove the inlet supply clamp using Fuel Line Pliers 9539.
  14.  
  15. Remove both rubber lines at the pump.
  16.  
  17. Disconnect the pump electrical connectors.
  18.  
  19. Remove the pump mounting bolts.
  20.  
  21. Remove the pump assembly.
    CAUTION
    Do not crimp or bend the fuel line. Capture all fluids that flow out of connections.

  22.  

To install:

  1. Install the high pressure pump to the left cylinder head. Torque the mounting bolts to 10 ft. lbs. (14 N·m).
  2.  
  3. Connect the pump electrical connectors.
  4.  
  5. Install the fuel lines at the pump.
  6.  
  7. Install the inlet supply line clamp using Fuel Line Pliers 9539.
  8.  
  9. Install the return line clamp using Fuel Line Pliers 9539.
    CAUTION
    Do not crimp or bend the fuel line. Inspect sealing cone at line; replace the line if compression exists.

  10.  
  11. Install the high pressure fuel line retaining nuts. Torque the nuts to 24 ft. lbs. (33 N·m).
  12.  
  13. Install the high pressure line support bracket.
  14.  
  15. Install the negative battery cable.
  16.  
  17. Install the engine cover.
  18.  
  19. Start engine and check for leaks.
  20.  

 
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