Intake Manifold: Service and Repair

MANIFOLD - INTAKE

REMOVAL
1. Disconnect the battery negative cables.





2. Remove the charge air cooler outlet tube (6) from the air inlet housing (8).





3. Remove the engine oil dipstick tube mounting bolt.
4. Remove dipstick support at fuel filter housing. Position dipstick tube to the side.
5. Disconnect the air grid heater power cables at the cable mounting studs.
6. Remove the engine wiring harness connections at the air inlet housing elbow.
7. Remove the four (4) air inlet housing mounting bolts and remove the housing from top of the heater elements.
8. Remove the intake air grid heater (1) from the manifold.
9. Remove the high pressure fuel lines and fuel rail.
10. Disconnect manifold air temperature/pressure sensor connector.
11. Remove the remaining intake manifold cover-to-cylinder head bolts.
12. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air intake.
13. Clean the intake manifold cover and cylinder head sealing surface.

CLEANING
Clean manifold in solvent and blow dry with compressed air.
Clean cylinder block gasket surfaces using a suitable solvent.
The plenum pan rail must be clean and dry (free of all foreign material).

INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness with a straightedge.

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 fuel rail. Tighten the bolts to 24 Nm (18 ft. lbs.) torque.
3. Install the high pressure rail and fuel lines.
4. Using two (2) new gaskets, install the intake air grid heater and air inlet housing.
5. Connect the manifold air temperature/pressure sensor connector.
6. Install and tighten the air intake heater power supply nuts to 14 Nm (120 inch lbs.) torque.
7. Install oil dipstick tube support at fuel filter housing.
8. Install the engine oil dipstick tube and mounting bolt.
9. Position the charge air cooler outlet tube onto the air inlet housing. Tighten the clamps to 11 Nm (100 inch lbs.) torque.
10. Attach the engine wire harness to the air inlet housing at two locations.
11. Prime the fuel system.
12. Connect the battery negative cables.