Intake Manifold Tube Replacement

Intake Manifold Tube Replacement
Removal Procedure





1. Remove the left charged air cooler hose.
2. Remove the air intake duct.

Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

3. Remove the charged air cooler outlet duct from the intake.





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





6. Remove the air inlet tube to intake manifold tube bolt and nut.





7. Disconnect the intake air heater electrical connector.
8. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
9. Remove the engine harness clip from the air inlet tube.
10. Remove the air inlet tube nuts.
11. Remove the air inlet tube.





12. If necessary, remove the intake manifold tube.
13. If necessary, remove and discard the 2 O-ring seals from the tube.
14. Clean the gasket surfaces of the exhaust gas recirculation (EGR) cooler tube, intake manifold tube and inlet tube.

Installation Procedure





1. If necessary, install NEW O-ring seals onto the tube.
2. If necessary, install the intake manifold tube.





3. Install the air inlet tube and NEW gaskets.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the air inlet tube nuts.
Tighten the nuts to 25 Nm (18 ft. lbs.).
5. Connect the intake air heater electrical connector.
6. Connect the MAP sensor electrical connector.
7. Install the engine harness clip to the air inlet tube.





8. Install the air inlet tube to intake manifold tube bolt and nut.
Tighten the bolt/nut to 10 Nm (89 inch lbs.).





9. Install the electrical harness bolts.
Tighten the bolts to 4 Nm (35 inch lbs.).





10. Install the charged air cooler outlet duct to the intake.
11. Tighten the charged air cooler outlet duct to intake hose clamp.
Tighten the clamp to 6 Nm (53 inch lbs.).
12. Install the air intake duct.
13. Install the air cleaner outlet duct.