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 turbocharger or the bolt holes for either of the intake manifold bolts for reassembly.





1. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower).
3. Disconnect the gray engine harness electrical connector.
4. Remove the boost sensor relay from the lower intake manifold.





5. Remove the glow plug relay from the lower intake manifold.





6. Remove the electrical harness retaining dips and ground straps.
7. Remove the fuel line retaining clips.





8. Remove the lower intake manifold bolts and fuel line clips.
9. Remove the lower intake manifold and gaskets from the cylinder heads.
10. Inspect and clean the sealing surface on the cylinder heads.


Installation Procedure

Notice: Refer to Fastener Notice in 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 glow plug relay to the lower intake manifold. Refer to Glow Plug Relay Replacement (Federal) or Glow Plug Relay Replacement (California).
4. Install the boost sensor relay to the lower intake manifold. Refer to Boost Sensor Replacement.
5. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower).





6. Install the electrical harness retaining clips and ground straps.





7. Connect the gray engine harness electrical connector.
8. Connect the battery negative cables to the batteries. Refer to Battery Negative Cable Disconnect/Connect Procedure.