Dodge Sprinter. Manual — part 221
(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
9 - 22
ENGINE
VA
NOTE:
The
camshaft
housing
Must
Not
be
machined. Basic bore of the camshaft bearings will
be altered.
(7) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 13) CYLINDER
HEAD SPECIFICATIONS.
(8) Measure valve setback at points (2) indicated
(Fig. 13) CYLINDER HEAD SPECIFICATIONS.
NOTE: If measurement is less than dimension “2”
no further correct valve clearance compensation is
possible; replace the cylinder head.
CYLINDER HEAD SPECIFICATIONS
Description
Specification
Height of Cylinder Head
(1), With Out Camshaft
Housing
126.85mm to 127.15mm
Valve Set Back (2) With
New Valves and New
Valve Seat Rings
Exhaust Valve: 1.0mm -
1.4mm
Intake Valve: 1.1mm -
1.5mm
REMOVAL
REMOVAL - CYLINDER HEAD
(1) Disconnect negative battery cable.
(2) Position piston of cylinder #1 to ignition TDC.
(3) Raise and support vehicle.
(4) Install retaining lock # 8932 for crankshaft/
starter ring gear.
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90°C (194°F). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER
ONLY.
WEAR
PROTECTIVE
GLOVES,
CLOTHING AND EYE WEAR.
(5) Drain cooling system at radiator and crankcase
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE).
(6) Loosen the lower turbo support bracket bolt.
(7) Remove the upper support bracket bolt.
(8) Loosen the fasteners retaining the exhaust pipe
to the support bracket at the rear of the engine.
(9) Lower vehicle.
(10) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
(11) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
Fig. 13 Cylinder Head Measurments
1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK
VA
ENGINE
9 - 23
(12) Remove the camshaft housing at the cylinder
head (Fig. 14).
(13) Remove the high pressure pump.
(14) Remove the front head cover plate.
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS.
WEAR
PROTECTIVE
CLOTHING
WHEN HANDLING FUEL.
(15) Remove the high pressure fuel pump interme-
diate gear (Fig. 14).
(16) Disconnect the engine side of the engine har-
ness and set aside.
(17) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con-
nected.
(18) Remove the turbocharger oil supply line at
the cylinder head and turbocharger (Fig. 14).
(19) Disconnect the turbocharger at the exhaust
manifold (Fig. 14).
(20) Unbolt the transmission oil level indicator
tube fasteners from the cylinder head and engine
block (Fig. 14).
(21) Disconnect the upper radiator hose and by
pass hose at the thermostat housing (Fig. 14).
NOTE: Capture any fuel spillage when disconnect-
ing fuel lines.
(22) Disconnect the fuel line at the rear of the fuel
rail (Fig. 14).
Fig. 14 CAMSHAFT HOUSING
1 - CAMSHAFT HOUSING
9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL
10 - EXHAUST MANIFOLD
3 - FUEL PIPE
11 - COOLANT PIPE
4 - O-RING
12 - TURBOCHARGER
5 - COOLANT HOSE
13 - O-RING
6 - COOLANT HOSE
14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT
15 - BANJO BOLT
8 - BUSHING
16 - TAPPET
9 - 24
ENGINE
VA
(23) Remove upper timing case to cylinder head
bolts (Fig. 15).
NOTE: Loosen cylinder head bolts in the reverse
order of the tightening sequence.
(24) Remove cylinder head bolts and inspect (Refer
to 9 - ENGINE/CYLINDER HEAD - STANDARD
PROCEDURE).
(25) Remove cylinder head (Fig. 15).
NOTE: Carefully clean all mating surfaces and bolt
thread holes. Assure that no oil or grease is present
during reassembly.
(26) Clean all mating surfaces and blow out bolt
thread holes.
REMOVAL - CYLINDER HEAD FRONT COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TMNG
BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
SERVICE VEHICLE IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. RISK OF POISON-
ING FROM INHALING AND SWALLOWING FUEL.
RISK OF INJURY FROM SKIN AND EYE CONTACT
WITH FUEL. POUR FUELS ONLY INTO SUITABLE
AND
APPROPRIATELY
MARKED
CONTAINERS.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL.
(5) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP -
REMOVAL).
(6) Remove bolts attaching front cover.
NOTE: Lower portion of front cover is sealed with
RTV sealant. Carefully tug at front cover until it
loosens from cylinder head.
(7) Raise locking pawl of top guide rail and remove
cylinder head front cover (Fig. 16).
NOTE: Dowel pins are use as a guide during
assembly and must remain in the proper position to
assure a good sealing surface.
Fig. 15 CYLINDER HEAD
1 - CYLINDER HEAD BOLT
2 - CYLINDER HEAD
3 - DOWEL
4 - GASKET
5 - BOLT TO TIMING COVER
VA
ENGINE
9 - 25
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