Sprinter 3500 L5-2.7L DSL Turbo (2004)
Valve Cover: Service and Repair
CYLINDER HEAD COVER(S)
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect the air inlet and set aside.
3. Detach hose from oil separator.
4. Disconnect the camshaft position sensor.
5. Disconnect fuel injector and glow plug harness and set aside.
6. Remove fuel high pressure pipes and injectors.
7. Disconnect the out let line.
8. Remove cylinder head cover retaining bolts and remove cover (Fig. 24).
INSTALLATION
NOTE: Do Not tighten the cylinder head cover first. The fuel injectors are aligned by way of the cylinder head cover.
1. Fit cylinder head cover with new gasket and install bolts, hand tight (Fig. 24).
2. Insert all fuel injectors, tensioning claws and lines. Insert new bolts and tighten.
3. Tighten cylinder head cover bolts to 9 Nm (80 inch lbs.).
4. Install and properly route fuel injector and glow plug wiring harness, making appropriate connections.
5. Connect the camshaft position sensor.
6. Connect the return flow line.
7. Attach oil separator hose.
8. Connect negative battery cable.
WARNING: (Refer to FUEL SYSTEM WARNING).
WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT
PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
9. Start engine and inspect for leaks. Care must be take to observe the fuel system warning.
