Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 389

#8941 SLIDE HAMMER

#8942 OIL JET INSTALLER

#8944 REAR MAIN SEAL INSTALLER

#9307 VALVE SERVICE TOOLS

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ENGINE

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#8951 ASSEMBLY LINKS

#9285 FUEL LINE WRENCH

# 9286 GLOW PLUG PLIERS

#9295 COMPRESSION HOSE ADAPTOR

#9525 TIMING CHAIN GUIDE

# 9539 FUEL LINE PLIERS

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ENGINE

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AIR CLEANER ELEMENT

REMOVAL

(1) Remove heat shield.
(2) Disconnect air flow sensor from housing (Fig.

10).

(3) Unclip the air cleaner housing lid (Fig. 10).
(4) Remove air cleaner element (Fig. 10).

INSTALLATION

(1) Position and seat the air cleaner element into

the lower housing (Fig. 10).

(2) Install the housing cover and snap retainers

into place (Fig. 10).

(3) Install air flow sensor into housing cover and

connect. (Fig. 10).

(4) Connect the air cleaner restriction sensor (Fig.

10)..

(5) Install heat shield.

AIR CLEANER HOUSING

REMOVAL

(1) Disconnect the negative battery cable.
(2) Remove the heat shield.
(3) Remove the air flow sensor (Refer to 14 - FUEL

SYSTEM/FUEL

INJECTION/MANIFOLD

AIR

FLOW (MAF) SENSOR - REMOVAL).

(4) Disconnect the air intake pressure sensor,

unclip the top of the air cleaner housing and remove
(Fig. 11).

(5) Take out air cleaner element (Fig. 11).
(6) Detach bottom part of the air cleaner housing

at the body (Fig. 11).

(7) Take air intake hose out of inner fender and

out of the rubber bushing in the wheel housing liner,
then detach it at the bottom part of the air cleaner
housing (Fig. 11).

#9543 ADAPTOR

#9544 VIBRATION DAMPER PULLER

Fig. 10 AIR CLEANER ELEMENT

1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSING

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ENGINE

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(8) Remove bottom portion of the air cleaner hous-

ing out of the rubber bushings in the inner fender
and remove (Fig. 11).

INSTALLATION

NOTE: Ensure that the seal between the inner
fender well and the air intake hose is correctly
installed.

(1) Seat and retain bottom portion of the air

cleaner housing into the bushings on the inner
fender (Fig. 11).

(2) Install the air intake hose to the air cleaner

housing the align and install it in the inner fender
and wheel housing liner (Fig. 11).

(3) Install air cleaner element (Fig. 11).
(4) Install and clip air cleaner top to air cleaner

body and connect the air intake pressure sensor (Fig.
11).

(5) Install air flow sensor (Fig. 11).
(6) Install heat shield.
(7) Connect negative battery cable.

CYLINDER HEAD

DESCRIPTION

The cylinder head is made of high temperature

resistant aluminum alloy and features optimized spi-

ral swirl intake ducts and a separate camshaft hous-
ing made of die cast aluminum. The combustion
chamber features four valves per cylinder, central
injectors and glow plugs arranged slant wise. The
intake and exhaust valves have solid valve stems and
conical valve springs. The cylinder head is not ser-
viceable and must be replaced should a repair
become necessary.

STANDARD PROCEDURE

STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION

(1) Measure cylinder head bolts between points

shown (Fig. 12).

Cylinder Head

Bolts

Thread Diame-

ter

12 M

Length When

New

102 mm

Maximum

Length

104 mm

(2) If the cylinder head bolt length is greater than

the maximum allowable measurement, replace the
cylinder head bolts.

STANDARD PROCEDURE - MEASURE CYLIN-
DER HEAD SURFACE

NOTE: DO NOT machine the cylinder head surface.

(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - REMOVAL).

(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-

ness, porous and damage.

(5) Using a straight edge, measure cylinder head

and cylinder block flatness.

(6) Measure cylinder head height at point (1) indi-

cated and retain reading (Fig. 13).

Fig. 11 AIR CLEANER HOUSING

1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER

Fig. 12 Measuring Cylinder Head Bolts

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ENGINE

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