Sprinter 3500 L5-2.7L DSL Turbo (2004)
EGR Valve: Service and Repair
EGR Valve
REMOVAL
NOTE: The EGR and EGR Cooler are serviced as an assembly.
1. Disconnect the negative battery cable.
2. Partailly drain the cooling system (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
3. Lift up on the charge air hose retaining clip at the intake manifold and disconnect hose with seal
4. Disconnect the electrical connector at the EGR positioner.
5. Disconnect the EGR cooler hose.
6. Remove the EGR fasteners and EGR with cooler assembly.
INSTALLATION
1. Clean all gasket mating surfaces
2. Position the EGR positioner to the intake manifold with a new gasket, install bolts and tighten to 124 lbs in (14 Nm).
3. Connect the EGR positioner electrical connector.
4. Inspect the seal of the charge air inlet tube, replace as necessary .
5. Seat the charge air tube with gasket into the intake manifold and push down on the charge air tube retaining clip
6. Refill the cooling system (Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)
7. Connect negative battery cable.
