OEM 2003 Dodge Sprinter 3500 Fuel Injector

2003 Dodge Sprinter 3500 Fuel Injector Parts and Q&A

• Q: How to Service and Repair Fuel Injectors on 2003 Dodge Sprinter 3500?

  A: Take out the negative battery cable and place the engine cover aside to service and fix the fuel injectors. Lift up the vehicle, take out the lower radiator deflector plate and drain the coolant. Unhook the turbocharger down pipe part, remove the bolt holding the oil dipstick in and take out the tube from the oil pan. With the vehicle lowered, take off the upper radiator hose, the whole air cleaner assembly, all hoses and the charge air cooler inlet hose and then unclip the charge air cooler to turbocharger inlet adaptor from the air cleaner box assembly. Unfasten the turbocharger to right engine mount bracket, take off the steering coupler from the rear left gearbox and remove the battery as well as the PDC from the battery tray. After that, take out the charge air cooler outlet hose and remove the intake manifold from the engine mount bracket to the left. Cover that end of the air conditioning pipes with plastic bags and, using a wrench, loosen the connections at the compressor. Disconnect the pedal position sensor from the electrical connection, as well as the injectors. Disconnect the engine mount through bolts and the plate from the right engine mount sill before removing the funnel/water separator to the intake manifold. Apply a wrench socket at the injection line threads, take out the high-pressure line fitting and remove the retaining bolt and tension claw. Take out the fuel injectors after setting the engine lower-if they prove to be stuck, you should use an extraction claw instead of a tensioning claw and if it's necessary, remove the cylinder head cover. Carefully clean the injectors and their spaces, apply anti-seize lubricant to the body of each injector and install them with new seals. Mount the claws and tighten them first to 7 Nm (62 lb in) and then to 90°. Should the locking clamp be removed from the injector, put a new one back on. Place the fuel return line by the injectors and close the locking clips and then combine the high-pressure lines and reconnect all the electrical injector connections. Lift the engine and place the sill plate, then secure the engine mount through bolts to 40 Nm (30 lb ft). Attach the fuel/water separator to the manifold and plug the power line into the pedal position sensor. Then attach the A/C lines to the A/C compressor. Attach the intake manifold to the left engine mount bracket, hook the charge air cooler outlet hose to the intake manifold, fit the power steering reservoir to the bracket on the right mount and place the battery in its tray, connecting the PDC to the battery tray as well. Reattach the steering coupler on the gearbox for RHD vehicles, place the turbocharger on the corresponding right bracket, link the charge air cooler to its inlet on the turbo, attach the air cooler inlet hose, fit the air cleaner box along with its pipes and fit the upper radiator hose. First, raise the vehicle, insert the dipstick tube into the oil pan and tighten the bolt that keeps it in place, then attach the part for the turbocharger down pipe to the manifold, close the drain in the cooling system and place the lower radiator deflector plate. Drop the car down, finish the negative cable connection and secure the engine cover. Pour the right fluid into the cooling system and do not go near pulleys, belts or the fan while the engine is running, also avoiding wearing billowy clothing. Turn on the engine and scrutinize for leaks and once you are done, charge the air conditioning again.