Sprinter 2500 L5-2.7L DSL Turbo (2003)
1. Position piston of cylinder to be processed to TDC by rotating the crankshaft clockwise. DO NOT crank engine or rotate engine counter
clockwise.
2. Connect cylinder leak tester with adapters and pressurize the cylinder to 5 bar (73 psi).
3. Install lower valve spring retainer (Fig. 23).
4. Install valve stem seal (Fig. 25).
5. Install valve spring (Fig. 23).
6. Install valve spring retainer (Fig. 23).
NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at the top of each valve spring
retainer.
NOTE: Ensure that the valve keepers are seated properly.
7. Compress valve and install valve collets (Fig. 22).
8. Repeat procedure for each cylinder as necessary.
9. Remove special tooling from cylinder head.
10. Position piston of #1 cylinder to ignition TDC.
11. Install camshafts and check basic position.
12. Install top guide rail.
13. Install front cover at cylinder head.
14. Install timing chain tensioner with new gasket
15. Install cylinder head cover.
16. Install glow plugs.
WARNING: SERVICE VEHICLES IN A WELL VENTILATED AREA AND AVOID IGNITION SOURCES. RISK OF INJURY TO
SKIN AND EYES FROM FUEL JET FLOWING OUT.
17. Install injectors.
18. Reconnect 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 CLOTHING.
19. Start the engine and inspect for leaks. Care must be taken to observe the fuel system warning.
20. Install engine cover.
