Sprinter 2500 V6-3.0L DSL Turbo (2008)
Fuel Injector: Removal and Replacement
Left Cylinder Head
LEFT CYLINDER HEAD
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 engine cover.
3. Disconnect the fuel return hose at the injector by lifting up on retaining tab and wiggling hose free.
4. Loosen the high pressure fuel lines at the fuel rail.
5. Disconnect the high pressure line at the fuel injector.
6. Disconnect the fuel injector electrical connector.
7. Remove the fuel injector hold down.
NOTE: If injectors are tight, remove with special tool 9552.
8. Remove injectors and discard lower sealing washer.
9. Clean injectors and recesses.
Right Cylinder Head
RIGHT CYLINDER HEAD
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 engine cover.
3. Disconnect the fuel return hose at the injector by lifting up on retaining tab and wiggling hose free.
4. Loosen the high pressure fuel lines at the fuel rail.
5. Disconnect the high pressure fuel lines at the fuel injector.
6. Disconnect the fuel injector electrical connector.
7. Remove the fuel injector hold down.
NOTE: If injectors are tight, remove with special tool 9552.
8. Remove injectors and discard lower sealing washer.
9. Clean injectors and recesses.
Left Cylinder Head
LEFT CYLINDER HEAD
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.
NOTE: Any time a new injector is installed, or if an existing injector is installed in any location other than its original location, the injector
quantity adjustment procedure also called injector classification, must be performed.
1. Clean injectors and recesses.
NOTE: Do Not apply any lubricant to the fuel injector nozzle. Care must be taken not to restrict the discharge orifices in the nozzle.
2. Coat injector body with anti seize lubricant then install injectors with new sealing washers.
3. Install tensioning claws. Tighten fasteners in two stages, 7 Nm (62 lbs. in.) then 180°.
CAUTION: Inspect both ends of the fuel line and fittings. If there is any damage to the sealing surface, replace the fuel line.
4. Position fuel return line at injectors, hand tighten the high pressure fuel line at the fuel rail and at the injector.
5. Tighten the fuel line fitting at the fuel rail to 27 Nm ( 20ft. lbs.), and tighten the fuel line at the injector to 33 Nm (24 ft. lbs.).
6. Reconnect the fuel injector electrical connector.
