OEM 2008 Dodge Sprinter 3500 Intake Manifold

2008 Dodge Sprinter 3500 Intake Manifold Parts and Q&A

• Q: How to Properly Install an Intake Manifold and Its Associated Components on 2008 Dodge Sprinter 3500?

  A: It's important to clean the cylinder heads and intake manifold surfaces before installing the turbocharger. Place and fit the intake manifold gasket correctly and set the intake manifold upper thermostat housing bolts to 8.4 Nm (74 in. lbs.). Increase all remaining bolts to 16 Nm (142 in. lbs.) by starting at the middle and using a cross process to the bolts above the thermostat on the right, tightening those to 8.4 Nm (74 in. lbs.). Start by positioning the fuel filter, then harness the fuel filter supply and return pipe and last the fuel injector return fuel hose. Connect the engine wiring harness in the correct way and put in the left fuel rail, tightening it with 27 Nm (20 ft. lbs.) bolts. Look at the fuel lines, particularly around the barrel and change them if there is any problem. Attach the fuel rail transfer line at the same time you install the right fuel rail and tighten fuel rail bolts to 27 Nm (20 ft. lbs.) and the fuel pipe to 33 Nm (24 ft. lbs.). Fix the high-pressure lines of the fuel injector while tightening with 27 Nm (20 ft. lbs.) of power. Link the swirl valve motor wires to their sensor connector, the EGR and EGR temperature sensor connector and the coolant hose at the EGR housing. Be sure to position the EGR housing and its associated block gasket correctly on the oil housing so the turbocharger is not damaged during the first engine start. Set the turbocharger oil housing adaptor into place and attach the turbocharger. After that, secure the proper rear engine cover bracket and set up the transmission oil level indicator tube, then add the charge air outlet, EGR air control valve, glow plug module, air cleaner cover, air inlet, engine cover and strut tower support. Populate the engine with coolant and associate the negative battery cable. Take great care when examining high-pressure fuel lines that can contain fuel at very high pressure up to 1350 bar (19,580 psi) and try not to find leaks by holding a piece of cardboard on the valve with safety goggles and proper safety clothing on. Operate the engine, let it heat up, switch it off and be sure to look for leaks while it is off.