Sprinter 2500 L5-2.7L DSL Turbo (2003)
17. Connect the heater hose at the lower intake manifold support bracket.
18. Connect the fuel tube to the fuel pressure sensor located on the bottom side of the intake manifold (Figure 12).
19. Install the fuel filter and bracket assembly onto the frame.
20. Install the center fuel tube at the fuel filter (Figure 3).
21. Connect the inboard fuel hose at the fuel filter (Figure 3).
22. Install the steel high pressure pump-to-fuel rail tube (Figure 4). Tighten the tube nuts to 195 in. lbs. (22 N.m).
23. Using Special Tool 9285, install the five injector rail-to-injector crossover tubes (Figure 2). Tighten the tubes to 195 in. lbs. (22 N.m).
24. Install the upper radiator hose.
25. Install the brake booster vacuum hose (Figure 2).
26. Install the radiator coolant recovery bottle hose.
27. Install the two bolts for the rear aluminum intake manifold support bracket (Figure 2).
28. Install the intake manifold upper steel support bracket (Figure 2).
29. Inspect the EGR mixing chamber for excessive carbon build-up. Clean EGR mixing chamber, if required, using Mopar Throttle Body Cleaner (P/N
04897156AB).
30. Install the Exhaust Gas Recirculation (EGR) mixing chamber onto the intake manifold (Figure 1). Tighten the EGR mixing chamber bolts to 124 in.
lbs. (14 N.m).
31. Install the intake manifold charge air hose (Figure 1).
32. Fill the engine cooling system with coolant.
33. Connect the negative battery cable.
34. Start the engine and visually inspect for fuel leaks.
CAUTION:
It may take several seconds of engine cranking, several times, before the engine will start. This is due to air in the fuel tubes. Use care not to overheat
the starter during the starting process.
35. Install the engine fuel injector cover onto the engine (Figure 1).
