Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 391

(2) Hand start clean head bolts and tighten per

the following procedure:

• Install M12 cylinder head bolts finger tight (Fig.

15).

• Tighten bolts in numeric order starting with

number 1 to 15 N·m (133 lbs.in.) (Fig. 17).

• Tighten bolts in numeric order starting with

number 1 to 60 N·m (44 lbs.ft.) (Fig. 17).

• Install M8 timing chain cover to cylinder head

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

• Tighten M12 cylinder head bolts in numeric

order starting with number 1 an additional 90° (Fig.
17).

• Tighten M12 cylinder head bolts in numeric

order starting with number 1 an additional 90° again
(4 stages). (Fig. 17).

(3) Install fuel return flow line between rail and

high pressure pump (Fig. 14).

(4) Connect the coolant hoses to the thermostat

housing (Fig. 14).

(5) Connect the coolant pipe at the cylinder head

(Fig. 14).

(6) Reconnect transmission oil level indicator tube.

Tighten to 14 N·m (124 lbs. in.) (Fig. 14).

(7) Reconnect the turbocharger to the exhaust

manifold. Tighten to 30N·m (22 lbs.ft.) (Fig. 14).

(8) Install oil return flow line with new seals at

turbocharger. Tighten bolt of supply line to turbo-
charger to 18N·m (160 lbs. in.) and bolt of supply line
to cylinder head to 9N·m (80 lbs. in.) (Fig. 14)

(9) Install charge air distribution pipe (Refer to 11

- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
INSTALLATION).

(10) Install and properly route the engine wiring

harness, making appropriate connections.

(11) Install high pressure fuel pump intermediate

gear (Fig. 14).

(12) Install high pressure pump (Refer to 14 -

FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).

(13) Install the camshaft housing with tappets to

cylinder head (Fig. 14).

(14) Install camshafts (Refer to 9 - ENGINE/CYL-

INDER HEAD/CAMSHAFT(S) - INSTALLATION).

(15) Install top guide rail (Refer to 9 - ENGINE/

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - INSTALLATION).

(16) Install front cover at cylinder head (Refer to 9

- ENGINE/CYLINDER HEAD - INSTALLATION).

(17) Install cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION).

(18) Install fuel high pressure pipes and injectors

(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).

(19) Install timing chain tensioner with new gas-

ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
Tighten to 80N·m (59 lbs.ft.).

(20) Remove retaining lock for crankshaft/starter

ring gear.

(21) Install air intake tube at turbocharger (Refer

to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM - INSTALLATION).

(22) Install

the

fasteners

retaining

the

front

exhaust pipe to the support bracket at the read of
the engine.

(23) Install the upper support bracket fastener.
(24) Install the lower turbo support bracket bolt.
(25) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

NOTE: DO NOT pressure test cooling system until
engine has reached operating temperature.

(26) Refill cooling system with proper coolant mix-

ture to proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).

(27) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(28) Start engine and inspect for leaks. Care must

be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING)

Fig. 17 CYLINDER HEAD BOLT TORQUE

SEQUENCE

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ENGINE

9 - 27

INSTALLATION - CYLINDER HEAD FRONT
COVER

NOTE: Thoroughly clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.

NOTE: Dowel pins are used as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.

(1) Apply sealant to the marked surfaces with a

bead thickness of 1.5 ± 0.5 mm (Fig. 18).

NOTE: Install front cover of cylinder head within 10
minutes after applying sealant. Do not spread seal-
ing bead.

(2) Raise locking pawl of top guide rail and guide

front cover onto guide pins.

(3) Install bolts attaching front cover (Fig. 16)

Tighten bolts to 14N·m (124 lbs. in.).

WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
REMOVE SOURCES OF IGNITION FROM THE AREA.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH FUEL. POUR FUELS
ONLY

INTO

SUITABLE

AND

APPROPRIATELY

MARKED CONTAINERS.

(4) Install vacuum pump (Refer to 9 - ENGINE/

ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).

NOTE: Timing chain tensioner must be installed
with a new gasket.

(5) Install timing chain tensioner (Refer to 9 -

ENGINE/VALVE

TIMING/TIMING

BELT/CHAIN

AND SPROCKETS - INSTALLATION).

(6) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(7) Start the engine and inspect for leaks. Care

must be taken to observe the fuel system warning
(Refer to 14 - FUEL SYSTEM - WARNING)

INSTALLATION - CYLINDER HEAD GUIDE RAIL

(1) Carefully position the top guide rail onto the

guide pins.

(2) Counter hold the camshaft with an open end

wrench and install driver of inlet camshaft sprocket.
Tight bolt to 50N·m (37 lbs. ft.).

(3) Remove camshaft sprocket locking pin.
(4) Carefully raise locking pawl of top guide rail

and install front cover at cylinder head (Fig. 16).

(5) Install timing chain tensioner with new gasket

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN

AND

SPROCKETS

-

INSTALLA-

TION).

(6) Install engine cover (Refer to 9 - ENGINE/

CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).

(7) Reconnect negative battery cable.

WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(8) Start engine and inspect for leaks.

CAMSHAFT(S)

STANDARD PROCEDURE

STANDARD PROCEDURE - CHECKING CAM-
SHAFT POSITION

(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)

Fig. 18 CYLINDER HEAD COVER SEALING

SURFACE

1 - CYLINDER HEAD FRONT COVER
2 - SEALANT BEAD

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ENGINE

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(3) Remove injectors (Refer to 14 - FUEL SYS-

TEM/FUEL

INJECTION/FUEL

INJECTOR

-

REMOVAL).

(4) Clean injectors and recesses (Refer to 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).

(5) Remove cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL).

NOTE: Rotate engine at crankshaft only. DO NOT
crank engine at the camshaft and DO NOT rotate
the engine backward.

(6) Position piston of cylinder #1 to ignition TDC.
(7) Insert the locking pin (special tool #8929)

through first camshaft bearing cap into the hole in
the left inlet camshaft sprocket (Fig. 19).

NOTE: The two markings in the inlet camshaft
sprockets must be positioned opposite and mark-
ings of camshaft and camshaft bearing cap must be
aligned. If not, perform basic position of camshafts.

(8) Remove locking pin from camshaft bearing cap

hole.

(9) Install cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION).

(10) Install injectors (Refer to 14 - FUEL SYS-

TEM/FUEL

INJECTION/FUEL

INJECTOR

-

INSTALLATION).

Fig. 19 CHECKING CAMSHAFT POSITION

1 - CAMSHAFT SPROCKET ALIGNMENT DOTS
2 - CAMSHAFT LOCK POSITION
3 - INTAKE CAMSHAFT SPROCKET
4 - CAMSHAFT AND BEARING CAP ALIGNMENT MARKS
5 - CAMSHAFT LOCKING PIN (SPECIAL TOOL #8929)
6 - INTAKE CAMSHAFT SPROCKET

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ENGINE

9 - 29

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NO WEAR LOOSE CLOTHING.

(11) Start the engine and inspect for leaks.

STANDARD PROCEDURE - INSPECTING TAP-
PET CLEARANCE

(1) Check engine oil level, adjust as necessary.
(2) Warm

engine

to

operating

temperature

(approx. 80°C, 176°F).

(3) Remove the cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL).

(4) Rotate the engine by the crankshaft until the

camshaft, at the tappet to be tested, is at it’s base
circle (camshaft nose must point upward) (Fig. 20).

NOTE: Do not use a tool that will mar or damage
the tappet surface. If applied pressure is too strong
the tappet will appear to drop, but what happens is,
the valve opens.

(5) Use a pressing tool and apply pressure to the

tappet by hand (Fig. 20).

(6) If the tappet drops faster in comparison to the

other tappets, remove the camshaft and replace the
tappet.

REMOVAL

NOTE: Tappets are serviced Only when replacing
the camshaft housing. Inspect tappet clearance
(Refer

to

9

-

ENGINE/CYLINDER

HEAD/CAM-

SHAFT(S) - STANDARD PROCEDURE).

(1) Disconnect negative battery cable.
(2) Remove engine cover. (Refer to 9 - ENGINE -

REMOVAL).

WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)

(3) Remove

high

pressure

lines

and

injectors

(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).

(4) Remove cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL).

NOTE: Rotate engine at the crankshaft only. DO
NOT rotate the engine at the camshaft. DO NOT
rotate the engine backward.

(5) Position piston of cylinder #1 to ignition TDC.
(6) Lock inlet camshaft (Fig. 21).

Fig. 20 TAPPET CLEARANCE

1 - CAMSHAFT
2 - PRESSURE APPLICATION POINT
3 - HYDRAULIC TAPPET
4 - CAMSHAFT HOLD DOWN

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ENGINE

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