Intake Air Heater: Service and Repair

REMOVAL

Fig.26 Intake Manifold Air Heater Element Location:

The 2 intake manifold air heater elements are attached to a metal block located at the top of the intake manifold (Fig. 26). If servicing either of the heater elements, the entire block/element assembly must be replaced.
1. Disconnect both negative battery cables at both batteries.
2. Disconnect clamp from rubber hose at air intake housing.
3. Disconnect rubber hose at air intake housing.

Fig.28 Air Intake Housing (Rear View):

4. Remove engine oil dipstick tube mounting bolt (Fig. 28). Position dipstick tube to the side.
5. Disconnect heater electrical cables at cable mounting studs (Fig. 28).

Fig.27 Air Intake Housing (Front View):

6. Disconnect ground cable bolt and ground cable from housing (Fig. 27).
7. Remove 4 housing bolts (Fig. 28).
8. Remove air intake housing from top of heater elements.
9. Remove heater element assembly from intake manifold.
10. Clean old gasket material from air intake housing and intake manifold.
11. Clean old gasket material from both ends of heater block (Fig. 26).

INSTALLATION
The 2 intake manifold air heater elements are attached to a metal block located at the top of the intake manifold (Fig. 26). If servicing either of the heater elements, the entire block/element assembly must be replaced.
1. Using 2 new gaskets, position element assembly and air housing to intake manifold.
2. Position ground cable (Fig. 27) to air housing.
3. Install 4 housing bolts and tighten to 24 Nm (18 ft. lbs.) torque.
4. Connect heater cables at cable mounting studs (Fig. 28). Do not allow the cable eyelets to contact any other metal source other than the cable nuts/studs.
5. Install engine oil dipstick tube and mounting bolt.
6. Connect rubber hose to air intake housing.
7. Connect clamp to rubber hose at air intake housing.
8. Connect both negative battery cables at both batteries