Intake Air Heater: Service and Repair

INTAKE AIR HEATER REPLACEMENT

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Remove the intake manifold cover.
3. Remove the air cleaner outlet duct.




4. Remove the air cleaner assembly.
5. Remove the electrical harness bolts.
6. Reposition the harness clip from the intake manifold tube, as needed.




7. Remove the engine harness power lead nut (2) from the intake air heater stud.
8. Remove the engine harness power lead (1) from the intake air heater stud.




9. Remove the air inlet tube to intake manifold tube bolt and nut.
10. Disconnect the intake air heater electrical connector.
11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
12. Remove the engine harness clip from the air inlet tube.
13. Disconnect the exhaust gas recirculation (EGR) valve motor harness connector.
14. Remove the 4 screws that secure the EGR valve motor to the EGR valve.
15. Remove the EGR valve motor from the EGR valve.
16. Remove the air inlet tube.




17. Remove the intake air heater nuts and bolts.
18. Separate the air inlet tube from the intake air heater.
19. Remove the air inlet heater (IAH) and discard the IAH gasket.

INSTALLATION PROCEDURE
1. Install the IAH using a NEW gasket.




2. Install the air inlet tubes to the intake air heater.

NOTE: Refer to Fastener Notice.

3. Install the intake air heater nuts and bolts.

Tighten the bolts to 20 N.m (15 lb ft).




4. Install the air inlet tube to intake manifold tube bolt and nut.

Tighten the bolt/nut to 10 N.m (89 lb in).

5. Install the EGR motor to the EGR valve.
6. Install the EGR bolts.

Tighten the bolts to 20 N.m (15 lb ft).

7. Connect the EGR valve motor harness connector.
8. Connect the intake air heater electrical connector.
9. Connect the MAP sensor electrical connector.
10. Install the engine harness clip to the air inlet tube.




11. Install the engine harness power lead (1) to the intake air heater stud.
12. Install the engine harness power lead nut (2) to the intake air heater stud.

Tighten the nut to 10 N.m (89 lb in).




13. Install the electrical harness bolts.

Tighten the bolts to 4 N.m (35 lb in).

14. Install the air cleaner assembly.
15. Install the air cleaner outlet duct.
16. Install the intake manifold cover.
17. Connect the negative battery cable.