Sprinter 3500 L5-2.7L DSL Turbo (2004)
Fuel Rail: Service and Repair
REMOVAL
Fuel Rail
WARNING: NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK
OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY
MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.
1. Disconnect negative battery cable.
2. Remove the engine cover.
3. Disconnect the intake manifold air inlet duct and position aside.
4. Disconnect the fuel rail pressure and control valve wiring harness connectors.
5. Remove engine harness retaining bolts and unclip the engine harness from the fuel rail.
6. Remove injector high pressure lines.
7. Remove fuel rail retaining bolts.
CAUTION: When slackening and tightening fuel injection line union nuts, counter hold with wrench at threaded connection. ON NO ACCOUNT
exceed the tightening torque at any time. Do NOT crimp or bend lines.
NOTE: After removing lines, seal connections and ensure cleanliness.
8. Detach fuel return flow line to high pressure pump at rail.
9. Detach fuel return flow line at banjo bolt.
10. Remove fuel rail.
INSTALLATION
WARNING: NO FIRE, FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF
INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY
MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.
1. Loosely position fuel rail into proper position on the cylinder head and hand tighten the fasteners
2. Connect the fuel pressure control valve harness connector.
3. Connect the fuel return lines at the banjo bolt.
CAUTION: Inspect sealing cones at the lines. Replace as necessary. Ensure that all fuel pressure lines are exactly located in original position.