Sprinter 3500 L5-2.7L DSL Turbo (2004)
Do not loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.
5.
Remove the cap from the coolant recovery bottle.
6.
Open the draincock and drain about two quarts of coolant from the radiator or until the coolant level is below the EGR valve level. Close the
radiator draincock, remove the drain hose and save the coolant for later reuse.
7.
Disconnect the EGR valve electrical connector (Figure 2).
8.
Disconnect the EGR coolant hose (Figure 2).
9.
Remove the EGR valve fasteners and then remove the EGR valve assembly (Figure 2).
10.
Clean the intake manifold mating surface for the EGR valve gasket.
11.
Position the new EGR valve onto the intake manifold with the provided gasket (Figure 2).
12.
Install the EGR valve fasteners. Tighten the bolts evenly to 80 in-lbs (9 N.m).
13.
Connect the coolant hose to the new EGR valve (Figure 2). Make sure the hose clamp is positioned behind the upset bead.
14.
Connect the EGR valve electrical connector (Figure 2).
15.
Fill the radiator to the top with the coolant that was drained from the radiator and fill the coolant recovery bottle to the COLD MINIMUM level.
16.
With the heater control unit in the HEAT position, start and operate the engine with the recovery bottle cap in place.
17.
After the engine has reached normal operating temperate, shut the engine off and allow it to cool. When the engine is shut down coolant will be
drawn into the radiator from the recovery bottle.
18.
Add coolant to the recovery bottle as necessary to raise the container level to the COLD MINIMUM mark. Use a 50/50 mixture of ethylene-glycol
coolant and water if necessary.
19.
Repeat Steps 15-18 two times to ensure all air has been purged from the system.