Intake Manifold: Service and Repair

Intake Manifold

Removal
1. Disconnect the LH and RH battery ground cables.
2. Remove the LH battery.
3. Remove the air cleaner assembly.
4. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine.








5. Remove the upper radiator hose.
6. Remove the coolant reservoir.





7. NOTE: Engine side shown, charge air cooler side similar.

Remove the turbocharger-to-charge air cooler tube.





8. NOTE: Engine side shown, charge air cooler side similar.

Remove the charge air cooler-to-engine tube.





9. Remove the accessory drive belt.





10. Position the boot back and disconnect the generator B+ wire and electrical connector.





11. Remove the three bolts and the generator.
12. Remove the turbocharger and the turbocharger pedestal.





13. Remove the bolts and position the heater hose tube aside.
^ Remove and discard the O-ring.





14. Disconnect the Manifold Absolute Pressure (MAP) sensor hose.





15. Disconnect the engine coolant vent hose.
16. Remove the injector driver module.





17. Disconnect the Powertrain Control Module (PCM) electrical connector.





18. Disconnect the 12-pin and 8-pin electrical connector.





19. Disconnect the wiring retainer, injector pressure regulator and Injector Control Pressure (ICP) sensor electrical connector.





20. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.





21. Disconnect the oil pressure sensor electrical connector.





22. Disconnect the oil temperature sensor electrical connector.





23. Disconnect the Throttle Position (TP) control module electrical connector, if equipped.





24. Disconnect the TP sensor electrical connector.





25. Disconnect the pin-type retainer and water temperature sensor.





26. Disconnect the Intake Air Temperature (IAT) sensor electrical connector and wiring connector.





27. Disconnect the exhaust backpressure sensor and retaining clip.





28. Disconnect the Camshaft Position (CMP) sensor and position the engine wiring harness aside.





29. NOTE: Left side shown, right side similar.

Disconnect the eight fuel injectors. Remove the nut and the fuel injector wiring harness.





30. Disconnect the fuel line fittings.





31. NOTE: It is necessary to remove the filter and drain the housing.

Remove the four bolts and the oil filter housing.





32. Remove the bolt and the oil filter return tube.





33. Remove the fuel line.
^ Remove the bolt, and the banjo fitting from the fuel line.
^ Discard the sealing washers and remove the fuel line.





34. Remove the nuts and the turbocharger heat shield.





35. NOTE: Align the flat edge with the index feature located on the coolant supply port.

Twist the EGR cooler clamp and slide the EGR cooler hose down.





36. NOTE: Intake removed for clarity.

Remove the EGR cooler V-clamp and gasket.





37. Remove the bolts and the intake manifold.





38. Remove the intake manifold gaskets.
^ Clean and inspect the gaskets. Replace if necessary.
^ Clean and inspect the sealing surfaces.

Installation





1. Install the intake manifold gaskets.





2. Install the intake manifold and bolts and tighten in the following sequence.
1 Loosely install the bolts.
2 Tighten bolts 9 - 16 to 11 Nm (8 ft. lbs.).
3 Tighten all bolts to 11 Nm (8 ft. lbs.) in the sequence shown.





3. Install the gasket and the EGR cooler V-clamp.





4. Slide the EGR cooler hose up and rotate flat to lock.





5. Install the turbocharger heat shield and the nuts.





6. Install the fuel line.
^ Install new sealing washers.
^ Install the fuel line.
^ Install the banjo fitting and the bolt.





7. Install the oil filter return tube and bolt.
^ On new oil filter return tubes, tighten to 6 Nm (53 inch lbs.).
^ On used oil filter return tubes, tighten to 3 Nm (27 inch lbs.).





8. Install the oil filter and the four bolts.





9. Connect the fuel line fittings.





10. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.





11. Position the engine wiring harness and connect the CMP sensor electrical connector.





12. Connect the retaining clip and exhaust backpressure sensor electrical connector.





13. Connect the wiring retainer and the IAT sensor electrical connector.





14. Connect the water temperature sensor and the pin-type retainer.





15. Connect the TP sensor electrical connector.





16. Connect the TP control module electrical connector, if equipped.





17. Connect the oil temperature sensor electrical connector.





18. Connect the oil pressure sensor electrical connector.





19. Connect the EGR valve electrical connector.





20. Connect the wiring retainer, injector pressure regulator and ICP sensor electrical connectors.





21. Connect the 12-pin and 8-pin electrical connectors.





22. Connect the PCM electrical connector.
23. Install the injector driver module.





24. Connect the engine coolant vent hose and clamp.





25. Connect the MAP sensor hose.





26. NOTE: Install a new O-ring on the heater hose tube.

Install the heater hose tube and bolts.
27. Install the turbocharger pedestal and turbocharger.





28. Install the generator and the three bolts.





29. Connect the generator B+ wire land electrical connector and position the boot back.





30. Install the accessory drive belt.





31. NOTE: Engine side shown, charge air cooler side similar.

Install the charge air cooler-to-engine tube.





32. NOTE: Engine side shown, charge air cooler side similar.

Install the turbocharger-to-charge air cooler tube.
33. Install the coolant reservoir.





34. Install the upper radiator hose.
35. Install the LH battery.
36. Connect both battery ground cables.
37. Install the air cleaner assembly.
38. Install the cooling fan blade, clutch and shroud, 6.0L diesel engine.