Intake Manifold Replacement - Lower

Removal Procedure

Important: Do not attempt to remove the upper intake manifold with the lower intake manifold as an assembly. The upper and lower intake manifolds will not align with the turbo charger or the bolt holes for either of the intake manifold bolts for reassembly.

1. Disconnect the battery negative cable from the battery.
^ For the front battery, refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
^ For the auxiliary battery, refer to Battery Cable Replacement (Battery Cable Aux. Negative) in Starting and Charging.





2. Remove the upper intake manifold from the lower intake manifold.
3. Remove the boost sensor relay from the lower intake manifold.
4. Remove the glow plug relay from the lower intake manifold.
5. Remove the fuel line retaining clips.
6. Remove the electrical harness retaining clips and ground straps.
7. Remove the lower intake manifold bolts and fuel line clips.
8. Remove the lower intake manifold and gaskets from the cylinder heads.
9. Inspect and clean the sealing surface on the cylinder heads.

Installation Procedure

Notice: Refer to Fastener Notice Service Precautions.





1. Install the lower intake manifold bolts to the cylinder head.
^ Tighten the bolts to 42 Nm (31 ft. lbs.).
2. Install the fuel line retaining clips.
3. Install the electrical harness retaining clips and ground straps.
4. Install the glow plug relay to the lower intake manifold.
5. Install the boost sensor relay to the lower intake manifold.
6. Install the upper intake manifold to the lower intake manifold.
7. Connect the battery negative cables to the batteries.