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Intake Manifold con't
23. Remove or position aside the heat insulating wrap.
24. Disconnect the wiring retainer, injector pressure regulator valve and Injector Control Pressure (ICP) sensor (if equipped) electrical connectors.
25. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.
26. Disconnect the Engine Oil Pressure (EOP) sensor electrical connector.
27. Disconnect the engine oil temperature sensor electrical connector.
28. Disconnect the Exhaust Gas Recirculation (EGR) throttle position control module electrical connector.
29. Disconnect the EGR throttle position sensor electrical connector.
30. Disconnect the pin-type retainer and Engine Coolant Temperature (ECT) sensor.
31. Disconnect the Intake Air Temperature (IAT2) sensor electrical connector and wiring connector.
32. Disconnect the exhaust backpressure sensor and retaining clip.
33. NOTE: Left side shown, right side similar.
Disconnect the eight fuel injectors electrical connectors. Remove the nut and the fuel injector wiring harness.
34. NOTE: It is necessary to remove the fuel filter and drain the housing.
Disconnect the fuel line fittings.
35. NOTE: It is necessary to remove the oil filter and drain the housing.
Remove the four bolts and the oil filter housing.
36. Remove the bolt and the oil filter return tube.
37. Remove the fuel line.
^ Remove the bolt, and the banjo fitting from the fuel line.
^ Discard the sealing washers and remove the fuel line.
38. NOTE: Align the flat edge with the index feature located on the coolant supply port.
Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
Early build
39. Remove the nuts and the turbocharger heat shield.
40. NOTE: Intake removed for clarity.
Remove the EGR cooler V-clamp and gasket.
41. Remove the bolts and the intake manifold.
Late build
42. Remove the nuts and the turbocharger heat shield.
43. Remove the EGR cooler V-clamp and gasket.
44. Remove the bolts and the intake manifold.
All vehicles
45. Remove the intake manifold gaskets.
^ Clean and inspect the gaskets. Install now gaskets if necessary.
^ Clean and inspect the sealing surfaces.
^ Remove and discard the front module O-ring seal.
Installation
All vehicles
1. NOTE: The locating tabs on the gaskets must be up and toward the center of the engine, or a leak will occur.
Install the intake manifold gaskets and front module O-ring seal.
Late build
2. Install the intake manifold and bolts and tighten in the following sequence.
1 Loosely install bolts 1-8.
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. Install the turbocharger heat shield and the nuts.
Early build
5. Install the intake manifold and bolts and tighten in the following sequence.
1 Loosely install bolts 1-8.
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.
6. Install the gasket and the EGR cooler V-clamp.
7. Install the turbocharger heat shield and the nuts.
All vehicles
8. Slide the EGR cooler hose forward and rotate flat to lock.
9. Install the fuel line.
^ Install new sealing washers.
^ Install the fuel line.
^ Install the banjo fitting and the bolt.
10. 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.).
11. Install the oil filter housing and the four bolts.
^ Clean and inspect the housing O-rings. Install new O-rings if necessary.
12. Connect the fuel line fittings.
13. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.
14. Connect the retaining clip and exhaust backpressure sensor electrical connector.
15. Connect the wiring retainer and the IAT2 sensor electrical connector.
16. Connect the engine coolant temperature (ECT) sensor and the pin-type retainer.
17. Connect the EGR throttle position sensor electrical connector.
18. Connect the EGR throttle position control module electrical connector.
19. Connect the engine oil temperature (EOT) sensor electrical connector.
20. Connect the engine oil pressure (EOP) sensor electrical connector.
21. Connect the EGR valve electrical connector.
22. Connect the wiring retainer, injector pressure regulator and ICP sensor (if equipped) electrical connectors.
23. Position back or install the heat insulating wrap.
24. Install the fuel injector control module. Refer to Computers and Control Systems.
25. Connect the engine coolant vent hose and clamp.
26. Connect the MAP sensor hose.
27. NOTE: Install a now O-ring on the heater hose tube.
Install the heater hose tube and bolts.
Early build
28. NOTE: Engine side shown, charge air cooler side similar.
Install the charge air cooler duct and tighten the clamps.
Late build
29. NOTE: Engine side shown, charge air cooler side similar.
Install the charge air cooler duct and tighten the clamp.
30. Install the turbocharger pedestal and turbocharger. Refer to Fuel Delivery and Air Induction.
31. Install the generator and the three bolts.
32. Connect the generator B+ wire land electrical connector and position the boot back.
Vehicles with single generator
33. Install the accessory drive belt.
Vehicles with dual generators
34. Install the generator with mounting bracket and bolts.
35. Connect the B+ wire, generator electrical connector and wire retainer.
36. Install the accessory drive belt tensioner and bolts.
37. Position the accessory drive belt idler pulley. Install the bracket and bolts.
38. Install the accessory drive belt.
39. Install the accessory drive belt tensioner and bolt.
40. Install the accessory drive belt.
All vehicles
41. NOTE: Engine side shown, charge air cooler side similar.
Install the turbocharger-to-charge air cooler duct.
42. Install the upper radiator hose.
43. Install the degas bottle. Refer to Cooling System.
44. Install the auxiliary battery. Refer to Battery.
45. Install the cooling fan stator - 6.0L diesel engine. Refer to Cooling System.