Sprinter 2005-2007

Cylinder Head (Valve) Covers

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Removal & Installation



2.7L Engine
  1. Disconnect negative battery cable.
  2.  
  3. Disconnect the air inlet and set aside.
  4.  
  5. Detach hose from oil separator.
  6.  
  7. Disconnect the camshaft position sensor.
  8.  
  9. Disconnect fuel injector and glow plug harness and set aside.
  10.  
  11. Remove fuel high pressure pipes and injectors.
  12.  
  13. Disconnect the out let line.
  14.  
  15. Remove cylinder head cover retaining bolts and remove cover
  16.  

To install:


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.
  2.  
  3. Insert all fuel injectors, tensioning claws and lines. Insert new bolts and tighten.
  4.  
  5. Tighten cylinder head cover bolts to 80 inch lbs. (9 N·m).
  6.  
  7. Install and properly route fuel injector and glow plug wiring harness, making appropriate connections.
  8.  
  9. Connect the camshaft position sensor.
  10.  
  11. Connect the return flow line.
  12.  
  13. Attach oil separator hose.
  14.  
  15. Connect negative battery cable.
  16.  
  17. Start engine and inspect for leaks.
  18.  

3.0L Engine
Left
  1. Disconnect negative battery cable.
  2.  
  3. Remove engine cover and bracket.
  4.  
  5. Remove air cleaner cover and inlet tube to turbocharger.
  6.  
  7. Remove the high pressure line (2) from the fuel pump and the fuel rail.

    Click image to see an enlarged view

    Fig. Remove high pressure fuel line (2), bracket (3), fuel temperature sensor connector (4) and intercooler air inlet tube (1).

  8.  
  9. Remove the bracket (3) from the oil filter housing.
  10.  
  11. Disconnect the fuel temperature sensor connector (4).
  12.  
  13. Disconnect the fuel quantity solenoid connector.
  14.  
  15. Remove the wiring harness retaining bolts and position the engine harness aside.
  16.  
  17. Remove the bolts from the intercooler air chamber.
  18.  
  19. Remove the turbo outlet to intercooler inlet air tube (1).
  20.  
  21. Remove the power brake booster vacuum line from the vacuum pump and position aside.
  22.  
  23. Disconnect the power feed line from the alternator and position aside.
  24.  
  25. Remove the supply and return fuel lines.
  26.  
  27. Disconnect the EGR solenoid connector.
  28.  
  29. Remove the EGR valve.
  30.  
  31. Disconnect the fuel injector electrical connectors.
  32.  
  33. Remove the fuel injector wiring harness from the cylinder head cover and position aside.
  34.  
  35. Remove the left cylinder head fuel return line.
  36.  
  37. Remove the high pressure fuel lines from the fuel injectors.
  38.  
  39. Remove the fuel injectors.
    CAUTION
    Care must be taken when removing the cylinder head cover. The cover is the camshaft retainer and end play interface. Do not pry on the cylinder head cover tabs.


    CAUTION
    The cylinder head cover is sealed with Mopar sealant that may be difficult when separating components. If the component are difficult to separate heat the sealed edges or area with a heat gun. DO NOT use any heat source that works with flame.


    NOTE
    Note the different length cylinder head cover bolts and their position for assembly purposes.

  40.  
  41. Remove the cylinder head cover fasteners and cover.
  42.  

To install:

  1. Clean and inspect all sealing surfaces.
    NOTE
    Care must be taken not to get any engine sealant on the camshaft journals of the cylinder head cover.

  2.  
  3. Install a 1 / 8 inch bead of Mopar® Engine RTV Gen II sealant to the underside of the cylinder head cover
  4.  
  5. Carefully position the cylinder head cover and install the bolts into their original position.
    CAUTION
    The cylinder head cover bolts are different lengths. Do not use the wrong length bolts or engine damage may result.

  6.  
  7. Tighten cylinder head cover bolts in sequence, first to 35 inch lbs. (4 N·m), and then repeat the sequence to 75 inch lbs. (8.4 N·m).

    Click image to see an enlarged view

    Fig. Tighten left cylinder cover bolts in sequence.

  8.  
  9. Install the EGR valve.
    CAUTION
    The fuel injector sealing washers MUST be replaced. DO NOT use the old sealing washers or double the sealing washers.


    NOTE
    Care must be taken not to apply any lubricant to the fuel injector nozzles.

  10.  
  11. Install the fuel injectors. Tighten the injector retaining claw bolt to 60 inch lbs. (7 N·m) and then an additional 180°.
  12.  
  13. Re-position and secure the engine harness.
  14.  
  15. Install the left fuel rail. Tighten the fuel rail bolts to 97 inch lbs. (11 N·m).
  16.  
  17. Position the return fuel lines and secure to the injectors. Push down on the release lock tab to secure.
  18.  
  19. Connect the fuel injector electrical connectors.
  20.  
  21. Install the left rear engine cover bracket.
  22.  
  23. Install the high pressure fuel lines from the fuel rail to injectors. Tighten the line connections to 20 ft. lbs. (27 N·m).
  24.  
  25. Install the fuel line from the high pressure pump to the left fuel rail. Tighten the retaining bolt to 22 ft. lbs. (30 N·m).
  26.  
  27. Install the fuel supply line to the fuel filter and high pressure pump.
  28.  
  29. Connect both fuel lines at the high pressure pump.
  30.  
  31. Install the air filter housing and tube.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine, run until warm, turn engine off and inspect for leaks.
  36.  

Right
  1. Disconnect the negative battery cable.
  2.  
  3. Position the coolant reservoir aside.
  4.  
  5. Remove the strut tower support.
  6.  
  7. Remove engine cover.
  8.  
  9. Remove engine cover front bracket.
  10.  
  11. Remove air cleaner cover and inlet tube to turbocharger.
  12.  
  13. Remove engine cover right rear bracket.
  14.  
  15. Remove the crankcase ventilation valve (CCV) and breather tube.
  16.  
  17. Disconnect the fuel return line.
  18.  
  19. Disconnect the fuel supply and return lines at the right cylinder head cover.
  20.  
  21. Disconnect the camshaft position sensor (CMP) and fuel injector wiring and position the right engine wiring harness aside.
  22.  
  23. Pull out on the fuel injector return fuel hose retainers, disconnect the hoses and position aside.
  24.  
  25. Remove the right fuel injectors.
  26.  
  27. Remove the air conditioning (A/C) heater hose bracket.
  28.  
  29. Remove the oil level indicator tube retaining bolt.
  30.  
  31. Remove the EGR air control valve assembly resonator.
  32.  
  33. Remove the vacuum pump.
  34.  
  35. Remove the cylinder head cover retaining bolts and remove cover.
  36.  

To install:

  1. Clean and inspect all sealing surfaces.
    NOTE
    Care must be taken not to get any engine sealant on the camshaft journals of the cylinder head cover.

  2.  
  3. Install a 1 / 8 inch bead of Mopar Engine RTV Gen II sealant to the underside of the cylinder head cover.
    CAUTION
    The cylinder head cover bolts are different lengths. Make sure to install the bolts into their original position.

  4.  
  5. Carefully position the cylinder head cover and install the bolts into their original position.
  6.  
  7. Tighten cylinder head cover bolts in sequence, first to 35 inch lbs. (4 N·m), and then repeat the sequence to 75 inch lbs (8.4 N·m).
    CAUTION
    Make sure to replace the lower copper washer seal on the injector. DO NOT re-use the old seal, DO NOT double the seals.



    Click image to see an enlarged view

    Fig. Tighten right cylinder head cover bolts in sequence.

  8.  
  9. Install the fuel injectors. Tighten the retaining claw bolts to 60 inch lbs. (7 N·m) and then an additional 180°.
  10.  
  11. Install the CCV housing. Tighten the fasteners to 80 inch lbs. (9 N·m).
  12.  
  13. Install the vacuum pump. Tighten the fasteners to 80 inch lbs. (9 N·m).
  14.  
  15. Install the EGR air control valve resonator. Tighten the fasteners to 80 inch lbs. (9 N·m).
  16.  
  17. Install the oil level indicator tube fastener. Tighten the bolt to 97 inch lbs. (11 N·m).
  18.  
  19. Install the A/C heater hose bracket. Tighten the bolts to 80 inch lbs. (9 N·m).
  20.  
  21. Install the fuel rail. Tighten bolts to 80 inch lbs. (9 N·m).
    NOTE
    Inspect all fuel lines for damage or wear. Replace as necessary. DO NOT over tighten the fuel line nuts.

  22.  
  23. Install the fuel injector high pressure lines. Tighten line nuts to 24 ft. lbs. (33 N·m).
  24.  
  25. Position the engine wiring harness and connect the CMP, fuel rail pressure sensor and fuel injectors.
  26.  
  27. Connect the fuel return hoses to fuel injectors, pushing down on the hose retainers.
  28.  
  29. Install the air cleaner cover and inlet tube.
  30.  
  31. Install the rear engine cover bracket.
  32.  
  33. Connect the CCV hose to air inlet tube and connect the CCV heater wiring harness connector.
  34.  
  35. Install the engine cover.
  36.  
  37. Install the strut tower support.
  38.  
  39. Install the coolant reservoir.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Start engine, allow to warm, turn engine off and inspect for leaks.
  44.  

 
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