Sprinter 2005-2007

Engine

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Removal & Installation



2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Evacuate and recover the A/C refrigerant.
  6.  
  7. Remove the front grille and fascia assembly.
  8.  
  9. Disconnect the engine wiring harness at the cabin side and carefully guide though the cowl into the engine area.
  10.  
  11. Remove the turbocharger heat shield.
  12.  
  13. Remove the engine appearance cover.
  14.  
  15. Remove the air cleaner and hose at the turbocharger and air cleaner assembly.
  16.  
  17. Disconnect the transmission lines at the radiator.
  18.  
  19. Disconnect the upper and lower radiator hoses.
  20.  
  21. Disconnect the A/C lines at the condenser.
  22.  
  23. Disconnect the condenser fan harness connector.
  24.  
  25. Disconnect the power steering cooler lines at the cooler.
  26.  
  27. Disconnect the charge air cooler hose at the intake manifold.
  28.  
  29. Remove charge air hose fasteners at the radiator closure panel.
  30.  
  31. Remove the fasteners retaining the radiator to the front crossmember.
  32.  
  33. Remove the change air cooler, A/C condenser and fan as an assembly.
  34.  
  35. Disconnect the charge air hose at the intake manifold.
  36.  
  37. Remove the radiator assembly.
  38.  
  39. Disconnect the high pressure and return hoses at the power steering pump.
  40.  
  41. Disconnect the fuel lines at the fuel filter.
  42.  
  43. Disconnect the refrigerant line at the A/C compressor.
  44.  
  45. Disconnect the vacuum line for the brake booster at the vacuum pump.
  46.  
  47. Disconnect the coolant hose of heating return flow at the water pump.
  48.  
  49. Disconnect the coolant hose of the heater supply at the coolant pipe at the side of the cylinder head.
  50.  
  51. Disconnect the air inlet, CCV breather hoses and CCV heater at the turbocharger.
  52.  
  53. Raise and safely support the vehicle.
  54.  
  55. Disconnect the front exhaust at the turbocharger.
  56.  
  57. Disconnect the electrical connector at the transmission.
  58.  
  59. Disconnect the engine valley drain hose fastener from the transmission.
  60.  
  61. Remove the steering gear mounting bolts.
  62.  
  63. Disconnect the transmission cooler lines at transmission and oil pan.
  64.  
  65. Remove the torque converter access plate.
  66.  
  67. Remove the torque converter bolts.
  68.  
  69. Remove the crank position sensor.
  70.  
  71. Remove the transmission housing to engine mounting bolts.
  72.  
  73. Remove the starter mounting bolts.
  74.  
  75. Support the transmission with a suitable transmission jack.
  76.  
  77. Place a wood block between the transmission housing and the front frame cross over.
  78.  
  79. Remove the transmission jack.
  80.  
  81. Remove the exhaust bracket (right side)
  82.  
  83. Remove the engine ground strap (left side).
  84.  
  85. Lower the vehicle.
  86.  
  87. Remove the heater housing filter and lower housing.
  88.  
  89. Connect Special Tool 9308 Engine Lifting Fixture to the engine lifting eyes.

    Click image to see an enlarged view

    Fig. Attach Special Tool 9308 (3) to the engine, then connect the engine hoist (1) to the center eyelet (2)-2.7L Engine removal

  90.  
  91. Remove the engine mount bolts.
  92.  
  93. Remove the transmission oil level indicator tube mounting bolt.
  94.  
  95. Using tin snips, remove the front cross plate at the cutting edges and deburr.

    Click image to see an enlarged view

    Fig. Cut the front cross plate (2) at the area indicated (1)-2.7L Engine removal

  96.  
  97. Connect and engine hoist and carefully lift engine assembly from engine bay area.
  98.  

To install:

  1. Install the engine assembly into the vehicle engine compartment, mating the transmission and the engine.
  2.  
  3. Lower the engine assembly until the engine brackets align with the mounts.
  4.  
  5. Hand start the engine mount bolts and remove the engine lifting device. Tighten the engine mount bolts to 62 ft. lbs. (83 Nm).
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Install the transmission housing to engine bolts. For additional information, refer to the following section, "Automatic Transmission, Removal & Installation.-
  10.  
  11. Install the torque converter bolts. For additional information, refer to the following section, "Automatic Transmission, Removal & Installation.-
  12.  
  13. Install the crankshaft position sensor.
  14.  
  15. Install the torque converter access plate.
  16.  
  17. Install the transmission cooler lines to transmission.
  18.  
  19. Connect the engine valley drain hose to the transmission.
  20.  
  21. Install the transmission electrical connector and shifter hardware.
  22.  
  23. Install the steering gear.
  24.  
  25. Install the starter.
  26.  
  27. Connect the ground strap (left side).
  28.  
  29. Align and install the exhaust and bracket.
  30.  
  31. Lower the vehicle.
  32.  
  33. Install the lower heater housing and filter.
  34.  
  35. Install the air inlet hose, CCV breather and CCV heater at the turbocharger.
  36.  
  37. Connect the coolant supply and return hoses.
  38.  
  39. Connect the brake booster vacuum hose at the vacuum pump.
  40.  
  41. Connect the fuel lines at the filter assembly.
  42.  
  43. Connect the power steering hoses.
  44.  
  45. Install the radiator/charge air cooler and hose(s) assemblies.
  46.  
  47. Install A/C condenser and fan assemblies Connect the fan harness connector.
  48.  
  49. Connect the refrigerant lines.
  50.  
  51. Install an air conditioning receiver/drier.
  52.  
  53. Connect the upper and lower radiator hoses.
  54.  
  55. Connect the transmission lines at the radiator.
  56.  
  57. Install air cleaner housing and connect the air inlet duct and air flow sensor.
  58.  
  59. Connect the charge air cooler hose at intake manifold.
  60.  
  61. Route the engine wiring harness inside the vehicle and connect.
  62.  
  63. Install the turbocharger heat shield.
  64.  
  65. Install the front grille and fascia assembly.
  66.  
  67. Check and fill the engine oil.
  68.  
  69. Refill the cooling system to the correct level.
  70.  
  71. Evacuate and recharge the A/C refrigerant.
  72.  
  73. Start engine and check for leaks
  74.  

3.0L Engines
  1. Remove the hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove air intake hose downstream of air filter on air filter housing.
  8.  
  9. Disconnect electrical connectors.
  10.  
  11. Disconnect the jump-starting point on air filter housing and place to one side.
  12.  
  13. Pull out air intake hose upstream of air filter on front module.
  14.  
  15. Lift the air filter housing at front from front module and pull out of the rear guides.
  16.  
  17. Remove the air filter housing bracket from the bulkhead.
  18.  
  19. Disconnect the electrical connector at the intake manifold pressure sensor.
  20.  
  21. Remove the intake manifold pressure sensor.
  22.  
  23. Remove hot film mass air flow sensor.
  24.  
  25. Remove the holder for air filter housing to front plate.
  26.  
  27. Remove the trim panel on right cylinder head cover.
  28.  
  29. Remove the trim panel on left cylinder head cover.
  30.  
  31. Place the gearshift into neutral.
  32.  
  33. Disconnect and remove the auxiliary battery.
  34.  
  35. Remove the battery tray for the auxiliary battery.
  36.  
  37. Raise and safely support the vehicle.
  38.  
  39. Disconnect the speed sensors on transmission.
  40.  
  41. Disconnect the oxygen sensors.
  42.  
  43. Remove the coolant lines from the heater core.
  44.  
  45. Remove the upper and lower radiator hoses from the radiator and position aside.
  46.  
  47. Remove the vacuum line at the vacuum pump.
  48.  
  49. Disconnect the engine ground.
  50.  
  51. Disconnect the Engine Control Module (ECM).
  52.  
  53. Remove the power steering lines at the power steering pump and cap the lines.
  54.  
  55. Remove the clamp and disconnect exhaust system between catalytic converter and diesel particulate filter.
  56.  
  57. Remove the driveshaft center support bearing on frame floor assembly.
  58.  
  59. Detach power take-off connections.
  60.  
  61. Remove the bolts, and remove driveshaft and hang to the side outside the working area.
  62.  
  63. Insert a suitable wooden block between the transmission and crossmember.
  64.  
  65. Attach engine removal chains to the lift points.

    Click image to see an enlarged view

    Fig. Attach the engine chains to the lift points (1,2)-3.0L Engine

  66.  
  67. Remove the bolts from the right engine mount at the front.
  68.  
  69. Remove the bolts from the left engine mount at the front.
  70.  
  71. Using a suitable engine hoist, lift the engine and transmission assembly from the vehicle.
  72.  

To install:

  1. Using a suitable engine hoist, lower the engine and transmission assembly into the vehicle.
  2.  
  3. Install the front right and left engine mount bolts.
  4.  
  5. Remove the engine removal chains.
  6.  
  7. Install the rear engine mount.
  8.  
  9. Connect the driveshaft.
  10.  
  11. Attach the power take-off connections.
  12.  
  13. Install the driveshaft center support bearing on frame floor assembly.
  14.  
  15. Connect the exhaust system between the catalytic converter and diesel particulate filter.
  16.  
  17. Install the power steering lines at the power steering pump.
  18.  
  19. Connect the ECM and engine ground.
  20.  
  21. Install the vacuum line at the vacuum pump.
  22.  
  23. Connect the upper and lower radiator hoses at the radiator.
  24.  
  25. Connect the coolant lines to the heater core.
  26.  
  27. Connect the oxygen sensors.
  28.  
  29. Connect the speed sensors on transmission.
  30.  
  31. Install the battery tray for auxiliary battery and install the auxiliary battery.
  32.  
  33. Install the trim panel on left cylinder head cover.
  34.  
  35. Install the trim panel on right cylinder head cover.
  36.  
  37. Install the holder for air filter housing to front plate.
  38.  
  39. Install the hot film mass air flow sensor.
  40.  
  41. Install the intake manifold pressure sensor.
  42.  
  43. Connect the electrical connector at intake manifold pressure sensor.
  44.  
  45. Install the air filter housing bracket to the bulkhead.
  46.  
  47. Connect the jump-starting point on air filter housing and place to one side.
  48.  
  49. Install air intake hose downstream of air filter on air filter housing.
  50.  
  51. Refill the engine cooling system to the correct level.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Install the engine hood
  56.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the power steering fluid.
  8.  
  9. Remove the air intake assembly.
  10.  
  11. Remove the grill.
  12.  
  13. Remove the headlight trim panel.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Remove the license plate holder and step grip plate.
  18.  
  19. Remove the front fascia assembly.
  20.  
  21. Lower the vehicle.
  22.  
  23. Drain the power steering fluid from the power steering fluid reservoir.
  24.  
  25. Disconnect the power steering fluid lines.
  26.  
  27. Disconnect the A/C pressure sensor.
  28.  
  29. Remove the condenser line bolt.
  30.  
  31. Remove the condenser lines.
  32.  
  33. Remove the transmission cooler lines from the radiator.
  34.  
  35. Remove the heater hose lines from the extension line.
  36.  
  37. Remove the upper and lower radiator hoses.
  38.  
  39. Matchmark the radiator support location on the frame.
  40.  
  41. Disconnect the electric fan connector.
  42.  
  43. Remove the cooling module assembly.
  44.  
  45. Disconnect the canister purge lines and position aside.
  46.  
  47. Disconnect the fuel lines.
  48.  
  49. Disconnect the fuel lines at the fuel rail.
  50.  
  51. Disconnect the Powertrain Control Module (PCM) connectors and remove the PCM
  52.  
  53. Remove the transmission dip stick mounting bolts.
  54.  
  55. Disconnect the engine ground strap.
  56.  
  57. Disconnect the coolant level sensor.
  58.  
  59. Raise and safely support the vehicle.
  60.  
  61. Remove the torque converter bolts.
  62.  
  63. Disconnect the oxygen sensor connectors at the connector bracket.
  64.  
  65. Remove the bolts from the right and left exhaust flange.
  66.  
  67. Remove the starter. For additional information, refer to the following section, "Starter, Removal & Installation.-
  68.  
  69. Disconnect the alternator electrical connectors.
  70.  
  71. Remove all but the top bell housing bolt.
  72.  
  73. Remove the left motor mount bolt.
  74.  
  75. Remove the left motor mount bolt.
  76.  
  77. Lower the vehicle.
  78.  
  79. Support the transmission with a suitable jack.
  80.  
  81. Install a suitable engine lift to the engine.
  82.  
  83. Remove the last bellhousing bolt.
  84.  
  85. Remove the engine assembly from the vehicle.
  86.  

To install:

  1. Using an engine lift, lower the engine assembly into the vehicle.
  2.  
  3. Install a single bellhousing bolt and tighten to 28 ft. lbs. (38 Nm).
  4.  
  5. Install the right motor mount bolt and tighten to 42 ft. lbs. (58 Nm).
  6.  
  7. Install the left motor mount bolt and tighten to 42 ft. lbs. (58 Nm).
  8.  
  9. Remove the jack supporting the transmission assembly and remove the engine lift.
  10.  
  11. Connect the alternator electrical connector.
  12.  
  13. Install the remaining bellhousing bolts and tighten to 28 ft. lbs. (38 Nm).
  14.  
  15. Install the torque converter bolts and tighten to 37 ft. lbs. (50 Nm).
  16.  
  17. Install the starter motor.
  18.  
  19. Install the bolts for the left and right exhaust flanges and tighten to 15 ft. lbs. (20 Nm).
  20.  
  21. Connect the oxygen sensor electrical connectors.
  22.  
  23. Install the front lower sound shield.
  24.  
  25. Connect the coolant level sensor.
  26.  
  27. Connect the engine ground strap.
  28.  
  29. Install the transmission dipstick mounting bolts.
  30.  
  31. Install the PCM and connect the electrical connectors.
  32.  
  33. Connect the fuel lines to the fuel rail.
  34.  
  35. Connect the canister purge lines.
  36.  
  37. Connect the electric fan connector.
  38.  
  39. Install the radiator support. Make sure the radiator support location lines up with the marks made on the frame during the removal process.
  40.  
  41. Install the upper and lower radiator hose.
  42.  
  43. Install the heater hose lines to the extension line.
  44.  
  45. Install the transmission cooler lines to the radiator.
  46.  
  47. Install the condenser lines.
  48.  
  49. Connect the A/C pressure sensor.
  50.  
  51. Connect the power steering fluid lines.
  52.  
  53. Install the front fascia assembly.
  54.  
  55. Install the license plate holder and step grip plate.
  56.  
  57. Install the head lamp trim panel.
  58.  
  59. Install the grill assembly.
  60.  
  61. Install the air intake assembly.
  62.  
  63. Refill the engine with oil to the correct level.
  64.  
  65. Refill the power steering system with fluid to the correct level.
  66.  
  67. Refill the cooling system to the correct level.
  68.  
  69. Connect the negative battery cable.
  70.  
  71. Start the engine and check for leaks.
  72.  

 
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