Sprinter 2005-2007

Intake Manifold

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Removal & Installation



2.7L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the high pressure fuel lines.
  8.  
  9. Remove the fuel rail. For additional information, refer to the following section, "Injectors, Removal & Installation.-
  10.  
  11. Remove the fuel rail support block between cylinders no. 1 and no. 2.
  12.  
  13. Disconnect the charge air hose at the intake manifold.
  14.  
  15. Disconnect the EGR wiring harness connector.
  16.  
  17. Remove the bolt retaining the engine wiring harness to the intake manifold.
  18.  
  19. Disconnect the coolant hose at the EGR valve.
  20.  
  21. Disconnect both fuel lines at the fuel filter.
  22.  
  23. Remove the lower intake manifold support bracket.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Remove the rear intake manifold mounting bolts while accessible from below.
  28.  
  29. Lower the vehicle.
    NOTE
    Access to one of the intake manifold bolts is through a supplied hole in the manifold.

  30.  
  31. Remove the remaining intake manifold bolts, lift the intake manifold up and out while guiding the engine wiring harness and fuel lines through the openings in the intake manifold, then remove the gasket
  32.  

To install:

  1. Clean both mating surfaces and install a new intake manifold gasket with the intake manifold. Guide the engine wiring harness and fuel lines through the intake manifold openings. Tighten manifold bolts to 12 ft. lbs. (16 Nm) in a cross directional pattern beginning with the middle bolts and tightening outward to the ends.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the rear intake manifold bolts and tighten to 12 ft. lbs. (16 Nm).
  6.  
  7. Install the lower intake manifold support bracket and tighten the bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect both fuel lines to fuel filter assembly.
  12.  
  13. Connect the coolant hose at the EGR valve.
  14.  
  15. Secure the engine wiring harness and cable duct to the intake manifold. Tighten the fastener to 80 inch lbs. (9Nm).
  16.  
  17. Connect the EGR wiring harness connector.
  18.  
  19. Connect the fuel pressure sensor electrical connector
  20.  
  21. Install the fuel rail
    NOTE
    The high pressure fuel lines must be counter held when tightening to prevent damage.

  22.  
  23. Install the high pressure fuel lines.
  24.  
  25. Connect the charge air hose to the intake manifold.
  26.  
  27. Install the engine appearance cover.
  28.  
  29. Refill the cooling system to the correct level.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Start the engine and check for leaks.
  34.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove the air intake assembly.
  8.  
  9. Disconnect the Powertrain Control Module (PCM) and remove the PCM and mounting bracket.
  10.  
  11. Disconnect the fuel rail electrical connectors.
  12.  
  13. Remove the engine wiring harness bolts.
  14.  
  15. Position aside the engine wiring harness.
  16.  
  17. Remove the power brake booster vacuum line connector.
  18.  
  19. Disconnect the Mass Air Flow sensor.
  20.  
  21. Remove the Mass Air Flow sensor (MAF).
  22.  
  23. Remove the oil separator tube from the oil separator.
  24.  
  25. Disconnect the crankcase ventilation sensor hose.
  26.  
  27. Disconnect all four camshaft position sensors.
  28.  
  29. Disconnect the Short Runner connector.
  30.  
  31. Disconnect the throttle sensor connector.
  32.  
  33. Disconnect the Tumbler Valve Solenoid connector.
  34.  
  35. Disconnect the MAP Sensor harness connector.
  36.  
  37. Disconnect the Electronic throttle control solenoid connector.
  38.  
  39. Position the engine harness aside.
  40.  
  41. Disconnect the fuel injector harness connectors.
  42.  
  43. Remove the fuel rail. For additional information, refer to the following section, "Fuel Injectors, Removal & Installation.-
  44.  
  45. Disconnect the EVAP purge solenoid hose.
  46.  
  47. Disconnect the power brake booster vacuum line at the intake manifold.
  48.  
  49. Disconnect the air pump solenoid vacuum line.
  50.  
  51. Remove the intake manifold bolts and remove the intake manifold.
  52.  

To install:

  1. Position the intake manifold into place and install the mounting bolts.
  2.  
  3. Connect the air pump solenoid vacuum line.
  4.  
  5. Connect the power brake booster vacuum line at the intake manifold.
  6.  
  7. Connect the EVAP purge solenoid hose.
  8.  
  9. Install the fuel rail and connect the fuel line and injector electrical connectors.
  10.  
  11. Position the engine harness into place and install the engine harness bolts.
  12.  
  13. Connect the following to the engine wiring harness:

    Electronic throttle control solenoid connector
     
    MAF sensor
     
    Tumbler Valve Solenoid connector
     
    Throttle sensor connector
     
    Short Runner connector
     

  14.  
  15. Connect all four camshaft position sensors.
  16.  
  17. Connect the crankcase ventilation sensor hose.
  18.  
  19. Install the oil separator tube to the oil separator.
  20.  
  21. Install the power brake booster vacuum line connector.
  22.  
  23. Install the PCM brackets and install the PCM.
  24.  
  25. Install the air intake assembly.
  26.  
  27. Refill the cooling system to the correct level.
  28.  
  29. Connect the negative battery cable.
  30.  

 
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