Intake Manifold Cover
REMOVAL1. Disconnect the battery negative cables.
Fig. 54
2. Remove the charge air cooler outlet tube from the air inlet housing (Fig. 54).
3. Remove the engine oil dipstick tube mounting bolt (Fig. 54). Position dipstick tube to the side.
Fig. 55
4. Disconnect the air grid heater power cables at the cable mounting studs (Fig. 55).
5. Remove the four (4) air inlet housing mounting bolts (Fig. 55) and remove the housing from top of the heater elements.
Fig. 56
6. Remove the intake air grid heater from the manifold (Fig. 56).
7. Remove the high pressure fuel lines. Refer to Powertrain Management for the correct procedure.
8. Remove the remaining intake manifold cover-to-cylinder head bolts.
9. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air intake.
10. Clean the intake manifold cover and cylinder head sealing surface.
INSTALLATION
1. Using a new gasket, install the intake manifold cover.
2. Install the cover-to-cylinder head bolts that do not hold down the high pressure fuel line support brackets. Tighten the bolts to 24 Nm (18 ft. lbs.) torque.
3. Install the high pressure fuel lines. Refer to Powertrain Management for the correct procedure.
4. Install the high pressure fuel line support bracket-to-intake manifold cover bolts and tighten to 24 Nm (18 ft. lbs.) torque.
5. Using two (2) new gaskets, install the intake air grid heater and air inlet housing (Fig. 55). Position the ground cable and install and tighten the bolts to 24 Nm (18 ft. lbs.) torque.
6. Install and tighten the air intake heater power supply nuts to 14 Nm (120 in. lbs.) torque.
7. Install the engine oil dipstick tube and mounting bolt (Fig. 54).
8. Position the charge air cooler outlet tube onto the air inlet housing (Fig. 54). Tighten the clamps to 8 Nm (72 in. lbs.) torque.
9. Perform the fuel system air bleed procedure. Refer to Air Bleed Procedure in Powertrain Management.
10. Connect the battery negative cables.