Sprinter 2500 L5-2.7L DSL Turbo (2003)
NOTE:
The studs will keep the intake manifold gasket in position during intake manifold installation.
8. Transfer the fuel pressure sensor to the new intake manifold (Figure 12).
9. Transfer the heater hose and plastic tube to the new intake manifold (Figure 12).
10. Install the new intake manifold onto the engine.
11. Hand start all intake manifold retaining bolts except for where the intake manifold gasket retaining studs are located.
12. Remove the two intake manifold gasket retaining studs.
13. Install the two remaining intake manifold retaining bolts in the two positions the studs were removed.
14. Tighten all intake manifold retaining bolts. Start tightening bolts from the center of the manifold and work outwards. Tighten the bolts to 142 in.lbs.
(16 N.m).
15. Install the engine wiring harness using the following procedure:
a. Install the engine wiring harness into position on the engine.
NOTE:
The wiring harness routes between the second and third intake runners on the intake manifold.
b. Using Special Tool 9286, connect the five glow plug electrical connectors onto the glow plugs (Figure 6).
c. Connect the engine harness retaining bolt.
d. Connect the electrical connectors at the five fuel injectors (Figure 6).
e. Connect the ABS module connectors located under the battery.
f.
Connect all electrical connectors that are related to the engine harness.
g. Tie straps the engine wiring harness to the main wiring harness.
h. Feed the three engine wiring harness connectors through the dash panel opening in the dash panel and seat the rubber grommet (Figure 5).
i.
Connect the three engine electrical harness connectors located under the instrument panel.
16. Install the lower intake manifold support bracket.
