Intake Manifold Replacement (Upper)

REMOVAL PROCEDURE





1. Disconnect the battery negative cables from the batteries.
2. Remove the upper intake manifold cover.
3. Remove the air intake duct from the upper intake manifold.
4. Loosen the clamps on the hose between the turbocharger and the upper intake manifold.

IMPORTANT: In order to loosen the sealer, run a small screw driver (flat blade) between the hose and the upper intake manifold. Use caution as not to damage the hose.





5. Loosen the hose connecting the upper intake manifold and the turbocharger.
6. Slide the hose connecting the upper intake manifold and the turbocharger on to the upper intake manifold.
7. Remove the EGR Valve (L56 only) from the upper intake manifold.





8. Remove the brace (long for the L65 and short for the L56) from the turbocharger to the upper intake manifold.





9. Remove the upper intake manifold bolts from the lower intake manifold (L65 shown).
10. Remove the upper intake manifold and the gasket from the lower intake manifold.

INSTALLATION PROCEDURE

IMPORTANT: When replacing the upper intake manifold gasket for the L56, always replace the O-ring between the upper and lower intake manifolds. Failure to replace this O-ring will cause a driveability problem.





1. Install the upper intake manifold to the lower intake manifold.

NOTICE: Refer to Fastener Notice in Caution and Notices.

2. Install the mounting bolts.
Tighten the bolts to 23 Nm (17 lb ft).

3. Install the EGR valve to the upper intake manifold.
4. Install the air intake duct to the upper intake manifold.





5. Install the upper intake manifold cover.
Tighten the bolts to 12 Nm (106 lb in).

IMPORTANT: Apply a small amount of silicone sealant on the openings of the hose before installing it on the turbocharger and the upper intake manifold.

6. Slide the hose connecting from the upper intake manifold on to the turbocharger.
7. Tighten the clamps on the hose between the turbocharger and the upper intake manifold.





8. Install the brace (long for the L65 and short for the L56) from the turbocharger to the upper intake manifold.
9. Connect the battery negative cables to the batteries.