California Emissions
Intake Manifold Tube Replacement (California Emissions)Removal Procedure
1. Remove the turbocharger boost sensor bracket bolt.
2. Remove the turbocharger boost sensor with bracket.
3. Remove the intake air heater nut and wire terminal from the intake air heater.
4. Remove the intake air heater and gasket, if replacing the tube.
5. Remove the following fuel pipes and wiring harnesses:
^ The main fuel pipes.
^ The fuel junction block.
^ The fuel hoses to the fuel injection control module (FICM) and the FICM wiring harness.
^ The fuel pipes to the left fuel rail.
6. Remove the exhaust gas recirculation (EGR) cooling hose clamps.
7. Remove the EGR cooling hose.
8. Remove the EGR bolts/nuts.
9. Remove the EGR cooler bracket bolts.
10. Remove the EGR cooler bracket.
11. Remove the EGR and cooler.
12. Remove the intake manifold tube bolts/nuts.
13. Remove the intake manifold tube.
14. Remove and discard the gaskets.
15. Clean the intake manifold tube in cleaning solvent and air dry.
Installation Procedure
1. Install the intake manifold tube with NEW gaskets.
2. Install the intake manifold tube bolts/nuts.
Notice: Refer to Fastener Notice in Service Precautions.
3. Tighten the intake manifold tube bolts/nuts in the order shown.
^ Tighten the bolts/nuts to 9 Nm (80 inch lbs.).
4. Install the EGR cooler bracket.
5. Install the EGR and cooler.
6. Install the EGR cooler bracket bolts.
7. Install the EGR bolts and nuts.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
^ Tighten the nuts to 19 Nm (14 ft. lbs.).
8. Install the EGR cooling hose.
9. Install the EGR cooling hose clamps.
10. Install the following fuel pipes and wiring harnesses:
^ The main fuel pipes.
^ The fuel junction block.
^ The fuel hoses to the FICM and the FICM wiring harness.
^ The fuel pipes to the left fuel rail.
11. Install the intake air heater and gasket, if required.
^ Tighten the heater to 50 Nm (37 ft. lbs.).
12. Install the intake air heater terminal and nut.
^ Tighten the nut to 4 Nm (35 inch lbs.).
13. Install the turbocharger boost sensor with bracket.
14. Disconnect the wire terminal to the intake air heater.
15. Install the turbocharger boost sensor bracket bolt.
^ Tighten the bolt to 10 Nm (89 inch lbs.).