Federal Emissions

Intake Manifold Tube Replacement (Federal Emissions)

Removal Procedure





1. Remove the turbocharger.
2. Remove the exhaust gas recirculation (EGR) valve.
3. Disconnect the wire terminal from the intake air heater.
4. Remove the following fuel pipes and wiring harnesses:
^ The main fuel pipes.
^ The fuel junction block.
^ The fuel hoses to the fuel injection control module (FICM) and the FICM wiring harness.
^ The fuel pipes to the left fuel rail.
5. Remove the intake manifold tube bolts/nuts.
6. Pull?up the intake manifold tube in order to remove.
7. Remove and discard the gaskets.
8. Remove the intake air heater from the intake manifold tube, if replacing the tube.
9. Clean the intake manifold tube in cleaning solvent and air dry.

Installation Procedure






1. Notice:
Refer to Fastener Notice in Service Precautions.

Install the intake air heater, if removed.
^ Tighten the heater to 50 Nm (37 ft. lbs.).
2. Install the intake manifold tube with NEW gaskets.





3. Install the intake manifold tube bolts/nuts.
4. Tighten the intake manifold tube bolts/nuts in the order shown.
^ Tighten the bolts/nuts to 9 Nm (80 inch lbs.).
5. Install the following fuel pipes and wiring harnesses:
^ The main fuel pipes.
^ The fuel junction block.
^ The fuel hoses to the FICM and the FICM wiring harness.
^ The fuel pipes to the left fuel rail.
6. Install the intake air heater terminal and nut.
^ Tighten the nut to 4 Nm (35 inch lbs.).
7. Install the EGR valve.
8. Install the turbocharger.