Sprinter 2005-2007

Exhaust Manifold

Print

Removal & Installation



2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the exhaust heat shield.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the turbocharger support bracket.
  8.  
  9. Loosen the exhaust pipe to engine bracket fasteners at the rear of the engine block.
  10.  
  11. Remove the exhaust hanger fasteners at the muffler.
  12.  
  13. Disconnect the front exhaust pipe to turbocharger fastener.
  14.  
  15. Position the front exhaust pipe aside.
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove the air cleaner housing hose from the turbocharger and position aside.
  20.  
  21. Remove the turbocharger oil cooler lines.
  22.  
  23. Remove the turbocharger to exhaust manifold fasteners and remove turbocharger.
  24.  
  25. Remove the self-locking exhaust manifold fasteners.
  26.  
  27. Remove exhaust manifold.
  28.  

To install:

  1. Inspect exhaust manifold gasket surface for flatness with a straight edge.
  2.  
  3. Inspect exhaust manifold for cracks or distortion.
  4.  
  5. Install a new exhaust manifold gasket over the studs.
  6.  
  7. Position the exhaust manifold over to studs and tighten retaining nuts to 22 ft. lbs. (30 Nm).
    NOTE
    Replace the turbocharger oil cooler line banjo bolt seals before installing the oil cooler line.

  8.  
  9. Install the turbocharger.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install the front exhaust pipe to turbocharger.
  14.  
  15. Install the exhaust hanger fasteners at the muffler.
  16.  
  17. Tighten the exhaust hanger bracket to engine block.
  18.  
  19. Install the turbocharger support bracket.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the air cleaner duct to the turbocharger.
  24.  
  25. Install the exhaust heat shield.
  26.  
  27. Connect the negative battery cable.
  28.  

3.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Remove the turbo heat shield.
  6.  
  7. Remove the EGR tube, left side only.
  8.  
  9. Remove the exhaust elbow at the turbo.
  10.  
  11. Remove the exhaust manifold and gasket.
  12.  

To install:

  1. Clean the mating surfaces of any old gasket material.
  2.  
  3. Install the exhaust manifold with a new gasket. Tighten the nuts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the exhaust elbow to the turbocharger and tighten the bolts to 15 ft. lbs. (20 Nm) plus 90°.
  6.  
  7. Install the turbo heat shield and tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Install the EGR tube, left side only.
  10.  
  11. Install the engine appearance cover.
  12.  
  13. Connect the negative battery cable.
  14.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake assembly.
  4.  
  5. Remove the EGR valve, left side only.
  6.  
  7. Disconnect the exhaust back pressure sensor.
  8.  
  9. Remove the exhaust back pressure sensor.
  10.  
  11. Remove the catalytic converter to exhaust manifold bolts.
  12.  
  13. Remove the EGR line, left side only.
  14.  
  15. Remove the exhaust manifold bolts.
  16.  
  17. Remove the exhaust manifold and gasket.
  18.  

To install:

  1. Clean the mating surfaces of any old gasket material.
  2.  
  3. Install the exhaust manifold with a new gasket. Tighten the bolts to 98 inch lbs. (11 Nm).
  4.  
  5. Install the EGR line, left side only.
  6.  
  7. Install the catalytic converter-to-exhaust manifold nuts and tighten to 15 ft. lbs. (20 Nm).
  8.  
  9. Install the battery pressure sensor.
  10.  
  11. Install the EGR valve, left side only.
  12.  
  13. Install the air intake assembly.
  14.  
  15. Connect the negative battery cable.
  16.  

 
label.common.footer.alt.autozoneLogo