Intake Air Heater: Service and Repair
REMOVALIf servicing either of the heater elements, the entire block/element assembly must be replaced.
1. Disconnect both negative battery cables at both batteries. Cover and isolate ends of both cables.
2. Remove both the intake manifold air intake tube (above injection pump), and its rubber connector hose (2).
3. Lift 2 rubber covers (3) to gain access to 2 positive (+) cable nuts.
4. Remove two cable nuts (6) and remove 2 cables from studs.
5. Remove wiring harness clips.
6. Remove engine oil dipstick tube bracket from air inlet connection and fuel filter housing.
7. Remove four housing mounting bolts (1) and remove heater element assembly.
INSTALLATION
If servicing either of the heater elements, the entire block/element assembly must be replaced.
CAUTION: The heater elements are no longer grounded using an external ground strap. Grounding is now accomplished using two electrically conductive gaskets. Failure to use these gaskets will result in faulty heater element operation.
1. Using 2 new gaskets, position element assembly and air housing to intake manifold.
2. Install 4 housing bolts and tighten to 24 Nm (18 ft. lbs.) torque.
3. Connect 2 positive (+) heater cables at cable mounting studs. Do not allow either of the cable eyelets to contact any other metal source other than the cable nuts/studs.
4. Install engine oil dipstick tube and mounting bolt.
5. Connect rubber connector hose and intake tube to air intake housing. Tighten clamp bolts to 11 Nm (100 in. lbs.) torque.
6. Connect both negative battery cables at both batteries.