Part 1

Intake Manifold













Removal

All vehicles

1. Disconnect the battery ground cable. For additional information, refer to Battery.

2. Remove the cooling fan stator. For additional information, refer to Cooling System &/or Engine Block Heater.

3. Remove the turbocharger pedestal. For additional information, refer to Fuel Delivery and Air Induction.

Vehicles with dual generator

4. Remove the accessory drive belt.





5. Remove the bolt and the accessory drive belt tensioner.





6. Remove the accessory drive belt.





7. Remove the 3 bolts, the bracket and the accessory drive belt idler pulley.





8. Remove the 2 bolts and the accessory drive belt tensioner.





9. Disconnect the generator electrical connector and the B+ wire.





10. Remove the 4 bolts and the generator and mounting bracket as an assembly.





Vehicles with single generator

11. Remove the accessory drive belt.





All vehicles

12. Disconnect the electrical connector pushpin and remove the bolt and position the ground wire aside.





13. Remove the bolt and position the Manifold Absolute Pressure (MAP) assembly aside.





14. Remove the 3 bolts and position the wiring aside.





15. Remove the 3 bolts for the Charge Air Cooler (CAC) tube and oil fill tube.





16. Disconnect the oil fill tube at the valve cover.





17. Remove the 2 nuts, CAC tube, oil fill tube and bracket.





18. Disconnect the generator electrical connector, the B+ wire and the wiring pushpin.





19. Remove the transmission fluid indicator and tube nut.





20. Disconnect the pushpin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.





21. Remove the 3 bolts, ground wire and the generator.





22. Remove the 2 bolts and position the heater hose tube aside.
- Remove and discard the O-ring seal.





23. NOTE: It will be necessary to position back or remove the heat insulating wrap.

Disconnect the wiring retainer and the Fuel Injection Pressure Regulator (IPR) valve electrical connector.





24. Disconnect the EGR valve electrical connector.





25. Disconnect the Engine Oil Pressure (EOP) sensor electrical connector.





26. Disconnect the Engine Oil Temperature (EOT) sensor electrical connector.





27. Disconnect the pin-type retainer and Engine Coolant Temperature (ECT) sensor.





28. Remove the ECT sensor.
- Plug or cap the opening as needed.





29. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.





30. Remove the IAT2 sensor.
- Plug or cap the opening as needed.





31. Disconnect the 8 fuel injector electrical connectors.





32. Disconnect the wiring harness retainers and position the engine wiring harness aside as needed for intake manifold removal.





33. Disconnect the MAP sensor hose.





34. Disconnect the engine coolant vent hose.





35. Remove the secondary fuel filter and remove all fuel from the filter housing.





36. Disconnect the fuel tubes and banjo bolt at the secondary fuel filter.
- Remove and discard the sealing washers.





37. Disconnect the fuel tube at the fuel filter housing and remove the nut.





38. Remove the RH banjo bolt and fuel tube.
- Discard the sealing washers.





39. Remove the 2 bolts and the secondary fuel filter assembly.





40. 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.





41. Remove the 11 bolts, the 5 stud bolts and the intake manifold.

42. Remove the intake manifold gaskets and the front module O-ring seal.
- Discard the front module O-ring seal.

- Clean and inspect the intake manifold gaskets. Install new gaskets if necessary.

- Clean and inspect the sealing surfaces.