Exhaust Manifold - Dodge Sprinter 2006 Manual

9 - 68 ENGINE
Fig. 70 INTAKE MANIFOLD
1 - INTAKE BOLT ACCESS HOLE
2 - INTAKE MANIFOLD
3 - SUPPORT BRACKET
NOTE: Access to one of the intake manifold bolts is
through a supplied hole in the manifold.
(16) Rem ove t h e r em a in in g in t a ke m a n ifold bolt s,
lift t h e in t a ke m a n ifold u p a n d ou t wh ile gu idin g t h e
en gin e wir in g h a r n ess a n d fu el lin es t h r ou gh t h e
open in gs in t h e in t a ke m a n ifold, t h en r em ove t h e
ga sket (F ig. 70).
NOTE: Install the EGR valve with new gasket onto
the new intake manifold if the intake manifold is
being replaced.
INSTALLA TION
NOTE: If the intake manifold is being replaced,
install the EGR valve with new gasket.
(1) Clea n bot h m a t in g su r fa ces a n d in st a ll a n ew
in t a ke m a n ifold ga sket wit h t h e in t a ke m a n ifold.
Gu ide t h e en gin e wir in g h a r n ess a n d fu el lin es
t h r ou gh t h e in t a ke m a n ifold open in gs. Tigh t en m a n -
ifold bolt s t o 16 N·m (142 lbs. in .) in a cr oss dir ec-
t ion a l pa t t er n begin n in g wit h t h e m iddle bolt s a n d
t igh t en in g ou t wa r d t o t h e en ds.
(2) Ra ise a n d su ppor t t h e veh icle.
(3) In st a ll t h e r ea r in t a ke m a n ifold bolt s a n d
t igh t en t o 16 N·m (142 lbs. in .) (F ig. 70).
(4) In st a ll t h e lower
br a cket . Tigh t en bolt s t o 20 N·m (177 lbs. in .) (F ig.
70).
(5) Lower t h e veh icle.
in t a ke m a n ifold su ppor t
(6) Con n ect bot h fu el lin es t o fu el filt er a ssem bly
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY/
F UE L F ILTE R - INSTALLATION).
(7) Con n ect t h e coola n t h ose a t t h e E GR va lve
(F ig. 69).
(8) Secu r e t h e en gin e wir in g h a r n ess a n d ca ble
du ct t o t h e in t a ke m a n ifold. t igh t en fa st en er t o 9N·m
(80 in . lbs.).
(9) Con n ect t h e E GR wir in g h a r n ess con n ect or
(F ig. 69).
(10) Con n ect t h e fu el pr essu r e sen sor elect r ica l
con n ect or
(11) In st a ll t h e fu el r a il (Refer t o 14 - F UE L SYS-
TE M/F UE L DE LIVE RY/F UE L RAIL - INSTALLA-
TION).
NOTE: The high pressure fuel lines must be counter
held when tightening to prevent damage.
(12) In st a ll t h e h igh pr essu r e fu el lin es (Refer t o
14 - F UE L SYSTE M/F UE L DE LIVE RY/F UE L LINE S
- INSTALLATION).
(13) Con n ect t h e ch a r ge a ir h ose t o t h e in t a ke
m a n ifold (F ig. 69).
(14) In st a ll t h e en gin e cover (Refer t o 9 - E NGINE
- INSTALLATION).
(15) F ill t h e coolin g syst em .
(16) Con n ect t h e n ega t ive ba t t er y ca ble.
(17) St a r t t h e en gin e, r u n u n t il wa r m , t u r n en gin e
off a n d in spect for lea ks. Ca r e m u st be t a ken t o
obser ve t h e fu el syst em wa r n in g. (Refer t o 14 - F UE L
SYSTE M - WARNING).
EX H AU ST M AN I FOLD
REMOVAL
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Rem ove t h e exh a u st h ea t sh ield.
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Rem ove t h e t u r boch a r ger su ppor t br a cket .
(5) Loosen t h e exh a u st pipe t o en gin e br a cket fa s-
t en er s a t t h e r ea r of t h e en gin e block.
(6) Rem ove t h e exh a u st h a n ger fa st en er s a t t h e
m u ffler.
(7) Discon n ect t h e fr on t exh a u st pipe t o t u r bo-
ch a r ger fa st en er (F ig. 71).
VA