Dodge Sprinter. Manual — part 232
(5) Remove the fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(6) Remove the fuel rail support block between cyl-
inders #1 and #2 (Fig. 68).
(7) Disconnect the charge air hose at the intake
manifold (Fig. 69).
Fig. 68 FUEL INJECTORS AND HIGH PRESSURE
FUEL LINES
1 - FUEL RAIL
2 - HIGH PRESSURE FUEL INJECTOR LINES
3 - INTAKE MANIFOLD
4 - FUEL INJECTOR
5 - CRANKCASE VENTILATION BREATHER
6 - CAMSHAFT POSITION SENSOR
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(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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ENGINE
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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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ENGINE
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