Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 401

(8) Disconnect the EGR wiring harness connector

(Fig. 69).

(9) Remove the bolt retaining the engine wiring

harness to the intake manifold.

(10) Disconnect the coolant hose at the EGR valve.

NOTE: Collect and store any fluid spillage when
disconnecting components.

(11) Disconnect both fuel lines at the fuel filter

(Fig. 69).

(12) Remove the lower intake manifold support

bracket (Fig. 70).

(13) Raise and support the vehicle.
(14) Remove the rear intake manifold mounting

bolts while accessible from below.

(15) Lower the vehicle.

Fig. 69 INTAKE MANIFOLD

1 - CLIP

6 - ENGINE OIL COOLER

2 - INTAKE MANIFOLD

7 - HIGH PRESSURE FUEL RAIL

3 - EGR VALVE

8 - COOLANT TEMPERATURE SENSOR

4 - EGR VALVE COOLANT HOSE

9 - FUEL RAIL PRESSURE SENSOR

5 - FUEL FILTER

10 - CHARGE AIR HOSE

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NOTE: Access to one of the intake manifold bolts is
through a supplied hole in the manifold.

(16) Remove the remaining intake manifold bolts,

lift the intake manifold up and out while guiding the
engine wiring harness and fuel lines through the
openings in the intake manifold, then remove the
gasket (Fig. 70).

NOTE: Install the EGR valve with new gasket onto
the new intake manifold if the intake manifold is
being replaced.

INSTALLATION

NOTE: If the intake manifold is being replaced,
install the EGR valve with new gasket.

(1) Clean both mating surfaces and install a new

intake manifold gasket with the intake manifold.
Guide the engine wiring harness and fuel lines
through the intake manifold openings. Tighten man-
ifold bolts to 16 N·m (142 lbs. in.) in a cross direc-
tional pattern beginning with the middle bolts and
tightening outward to the ends.

(2) Raise and support the vehicle.
(3) Install the rear intake manifold bolts and

tighten to 16 N·m (142 lbs. in.) (Fig. 70).

(4) Install

the

lower

intake

manifold

support

bracket. Tighten bolts to 20 N·m (177 lbs. in.) (Fig.
70).

(5) Lower the vehicle.

(6) Connect both fuel lines to fuel filter assembly

(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL FILTER - INSTALLATION).

(7) Connect the coolant hose at the EGR valve

(Fig. 69).

(8) Secure the engine wiring harness and cable

duct to the intake manifold. tighten fastener to 9N·m
(80 in. lbs.).

(9) Connect the EGR wiring harness connector

(Fig. 69).

(10) Connect the fuel pressure sensor electrical

connector

(11) Install the fuel rail (Refer to 14 - FUEL SYS-

TEM/FUEL DELIVERY/FUEL RAIL - INSTALLA-
TION).

NOTE: The high pressure fuel lines must be counter
held when tightening to prevent damage.

(12) Install the high pressure fuel lines (Refer to

14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- INSTALLATION).

(13) Connect the charge air hose to the intake

manifold (Fig. 69).

(14) Install the engine cover (Refer to 9 - ENGINE

- INSTALLATION).

(15) Fill the cooling system.
(16) Connect the negative battery cable.
(17) Start the engine, run until warm, turn engine

off and inspect for leaks. Care must be taken to
observe the fuel system warning. (Refer to 14 - FUEL
SYSTEM - WARNING).

EXHAUST MANIFOLD

REMOVAL

(1) Disconnect the negative battery cable.
(2) Remove the exhaust heat shield.
(3) Raise and support the vehicle.
(4) Remove the turbocharger support bracket.
(5) Loosen the exhaust pipe to engine bracket fas-

teners at the rear of the engine block.

(6) Remove the exhaust hanger fasteners at the

muffler.

(7) Disconnect the front exhaust pipe to turbo-

charger fastener (Fig. 71).

Fig. 70 INTAKE MANIFOLD

1 - INTAKE BOLT ACCESS HOLE
2 - INTAKE MANIFOLD
3 - SUPPORT BRACKET

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(8) Position the front exhaust pipe aside.
(9) Lower the vehicle.
(10) Remove the air cleaner housing hose from the

turbocharger and position aside (Fig. 71).

(11) Remove the turbocharger oil cooler lines (Fig.

72).

(12) Remove the turbocharger to exhaust manifold

fasteners and remove turbocharger (Fig. 72).

(13) Remove the self locking exhaust manifold fas-

teners (Fig. 72).

(14) Remove exhaust manifold and clean mating

surface.

INSTALLATION

NOTE: Exhaust manifold surface must be flat within
0.006 in. per foot (0.15mm per 300mm) of manifold
length.

(1) Inspect exhaust manifold gasket surface for

flatness with a straight edge.

(2) Inspect exhaust manifold for cracks or distor-

tion.

(3) Install new exhaust manifold gasket over the

studs.

(4) Position the exhaust manifold over to studs

and tighten retaining nuts to 30 N·m (22 lbs.ft.).

NOTE: Replace the turbocharger oil cooler line
banjo bolt seals before installing the oil cooler line.

(5) Install turbocharger (Refer to 11 - EXHAUST

SYSTEM/TURBOCHARGER

SYSTEM/TURBO-

CHARGER - INSTALLATION).

(6) Raise and support the vehicle.
(7) Install the front exhaust pipe to turbocharger

(Fig. 71).

Fig. 71 TURBOCHARGER

1 - EXHAUST MANIFOLD
2 - HEATER PIPE
3 - AIR INLET TUBE
4 - TURBOCHARGER
5 - AIR CLEANER HOUSING
6 - EXHAUST CLAMP
7 - FRONT EXHAUST PIPE

Fig. 72 EXHAUST MANIFOLD

1 - CYLINDER HEAD
2 - TURBOCHARGER OIL COOLER LINE
3 - TIMING CHAIN TENSIONER
4 - BANJO BOLT
5 - EXHAUST MANIFOLD

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(8) Install the exhaust hanger fasteners at the

muffler.

(9) Tighten the exhaust hanger bracket to engine

block.

(10) Install the turbocharger support bracket.
(11) Lower the vehicle.
(12) Install the air cleaner duct to the turbo-

charger (Fig. 71).

(13) Install the exhaust heat shield.
(14) Connect the negative battery cable.

TIMING CHAIN COVER

REMOVAL

WARNING:

DO

NOT

OPEN

COOLING

SYSTEM

UNLESS TEMPERATURE IS BELOW 90°C (194°F).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE

COOLANT

IN

APPROVED

CONTAINER

ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING

COOLANT.

WEAR

PROTECTIVE

GLOVES, CLOTHING AND EYE WEAR.

(1) Disconnect negative battery cable.

NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.

NOTE: DO NOT crank engine back.

(2) Position piston of cylinder 1 to ignition TDC.

Markings on the camshaft bearing cap must be
aligned.

(3) Drain coolant (Refer to 7 - COOLING/ENGINE/

COOLANT - STANDARD PROCEDURE).

(4) Install retaining lock for crankshaft/starter

ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).

(5) Drain engine oil.
(6) Remove the oil filter to allow the oil to flow off

into the oil pan.

(7) Remove the radiator assembly (Refer to 7 -

COOLING/ENGINE/RADIATOR - REMOVAL).

(8) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(9) Remove front cover at cylinder head (Refer to 9

- ENGINE/CYLINDER HEAD - REMOVAL).

(10) Remove accessory drive belt.
(11) Remove the high pressure fuel pump (Refer to

14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).

(12) Remove water pump (Refer to 7 - COOLING/

ENGINE/WATER PUMP - REMOVAL).

(13) Remove accessory drive belt pulley and vibra-

tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
VIBRATION DAMPER - REMOVAL).

(14) Remove the power steering pump.

NOTE: NO NOT open the air conditioning system.

(15) Unplug AC compressor electrical connector

and unbolt AC compressor. Relocate in lower engine
compartment with out opening the system.

(16) Remove the generator with wiring attached

and relocate somewhere in the engine compartment.

(17) Install engine support fixture.
(18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat

exchanger at crankcase (Fig. 73).

(20) Remove the cylinder head to timing cover

bolts (Fig. 73).

(21) Remove the timing cover bolts and cover (Fig.

73).

(22) Remove

remaining

ancillary

components

attached to the timing case cover (Fig. 73).

NOTE: Inspect condition of hoses and clamps,
replace as necessary.

(23) Remove timing chain tensioner (Refer to 9 -

ENGINE/VALVE

TIMING/TIMING

BELT/CHAIN

AND SPROCKETS - REMOVAL)

(24) Remove timing case cover (Fig. 73).

Fig. 73 TIMING CHAIN COVER

1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER

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