Sprinter 2500 L5-2.7L DSL Turbo (2003)
20. Remove the cylinder head to timing cover bolts (Fig. 65).
21. Remove the timing cover bolts and cover (Fig. 65).
22. Remove remaining ancillary components attached to the timing case cover (Fig. 65).
NOTE: Inspect condition of hoses and clamps, replace as necessary.
23. Remove timing chain tensioner
24. Remove timing case cover (Fig. 65).
INSTALLATION
CAUTION: Care must be taken to closely inspect the gasket area around the time case cover to cylinder head gasket coolant port. If damage is
found, replace the cylinder head gasket. Failure to do so may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during assembly.
1. Inspect cylinder head gasket and oil pan gasket. If damaged, replace.
2. Replace the front crankshaft seal.
3. Install ancillary components to timing case cover.
4. Apply sealant to the marked surfaces with a bead thickness of 1.5 ± 0.5 mm (Fig. 66).
NOTE: Install timing cover within 10 minutes after applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the crankcase. Sealant applied at these points is entrained by the oil flow and blocks the oil supply
passages.
5. Position and install timing case cover. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 65).
6. Install the M8 bolts of cylinder head on timing case cover. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 65).
7. Install timing chain tensioner with new seal.
8. Position and install the oil pan. Tighten M6 bolts to 9 Nm (80 inch lbs.) and M8 bolts to 20 Nm (177 inch lbs.).
9. Install belt /pulley vibration damper. Tighten M8.8 bolt in two stages, 200 Nm (147 ft. lbs.) then 90°, M10.9 bolt 325 Nm (240 ft. lbs.) then 90°.
10. Remove the engine support fixture.
11. Install generator.
12. Install the air conditioning compressor.
13. Install the power steering pump.
14. Install water pump.
15. Connect coolant hose to oil-water heat exchanger.
16. Install high pressure fuel pump.
17. Apply sealant to lower portion of, and install, front cover to cylinder block. Tighten bolts to 20 Nm (177 inch lbs.).
18. Remove retaining lock for crankshaft/starter ring gear.
