Sprinter 2500 L5-2.7L DSL Turbo (2003)
openings in the intake manifold, then remove the gasket.
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 manifold bolts to 16 Nm (142 inch lbs.) in a cross directional 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 Nm (142 inch lbs.) (Fig. 63).
4. Install the rear coolant hose to the intake manifold and tighten clamp (Fig. 63).
5. Lower the vehicle.
6. Connect the fuel pressure sensor electrical connector (Fig. 63).
7. Install the right intake manifold support brackets. Tighten the bolts to 14 Nm (124 inch lbs.) (Fig. 63).
8. Install the lower intake manifold support bracket. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 63).
9. Connect both fuel lines to fuel filter assembly.
10. Connect the coolant hose at the connection junction above the lower intake manifold support bracket (Fig. 63).
11. Secure the engine wiring harness and cable duct to the intake manifold (Fig. 63).
12. Connect the EGR wiring harness connector (Fig. 63).
13. Connect the charge air hose to the intake manifold (Fig. 63).
14. Carefully route the engine wiring harness through and into the passenger compartment and reconnect.
15. Install the engine cover.
16. Fill the cooling system.
17. Connect the negative battery cable.
18. Start the engine and inspect for leaks. Care must be taken to observe the fuel system warning. Refer to FUEL SYSTEM - WARNING.
