Removal

Intake Manifold




Material

Removal

All vehicles
1. Disconnect the battery ground cable.
2. Remove the cooling fan stator.
3. Remove the turbocharger pedestal.

Vehicles with dual generator





4. Remove the accessory drive belt.





5. Remove the bolt and the accessory drive belt tensioner.





6. Remove the accessory drive belt.





7. Remove the bolts, bracket and accessory drive belt idler pulley.





8. Remove the bolts and the accessory drive belt tensioner.





9. Disconnect the generator electrical connector and the B+ wire.





10. Remove the bolts and the generator with mounting bracket.

Vehicles with single generator





11. Remove the accessory drive belt.

All vehicles





12. Remove the bolt and position the ground wire aside. Disconnect the electrical connector pushpin.





13. Remove the bolt and position the Manifold Absolute Pressure (MAP) assembly aside.





14. Remove the bolts and position the wiring aside.





15. Remove the bolts for the charge air cooler tube and oil fill tube.





16. Disconnect the oil fill tube at the valve cover.





17. Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.





18. Disconnect the generator electrical connector and the B+ wire. Disconnect the wiring pushpin.





19. Remove the retaining nut for the transmission fluid indicator and tube.





20. Disconnect the pushpin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.





21. Remove the three bolts, ground wire and the generator.





22. Remove the bolts and position the heater hose tube aside.
^ Remove and discard the O-ring seal.





23. NOTE: It will be necessary to position back or remove the heat insulating wrap.

Remove the retaining nut and disconnect the wiring retainer and the injection pressure regulator valve electrical connector.





24. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.





25. Disconnect the Engine Oil Pressure (EOP) sensor electrical connector.





26. Disconnect the Engine Oil Temperature (EOT) sensor electrical connector.





27. Disconnect the pin-type retainer and Engine Coolant Temperature (ECT) sensor.





28. Remove the ECT sensor.
^ Plug or cap the opening as needed.





29. Disconnect the Intake Air Temperature (IAT2) sensor electrical connector.





30. Remove the IAT2 sensor.
^ Plug or cap the opening as needed.





31. NOTE: Only one fuel injector shown, others similar.

Disconnect the eight fuel injector electrical connectors and wiring connectors.





32. NOTE: One retainer shown, others similar.

Disconnect the harness retainers. Position the engine wiring harness as needed for intake manifold removal.





33. Disconnect the Manifold Absolute Pressure (MAP) sensor hose.





34. Disconnect the engine coolant vent hose.





35. Remove the secondary fuel filter and remove all fuel from the filter housing.





36. Disconnect the fuel tube fittings at the secondary fuel filter.
^ Remove and discard the copper sealing washers.





37. Disconnect the fuel tube at the fuel filter housing. Remove the retaining nut.





38. Remove the banjo bolt and fuel tube.
^ Discard the copper sealing washers.





39. Remove the bolts and the secondary fuel filter assembly.





40. Remove the nuts and turbocharger heat shield.





41. NOTE: Align the flat edge with the index feature located on the coolant supply port.

Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.





42. Remove the bolts and the intake manifold.





43. Remove the intake manifold gaskets.
^ Clean and inspect the gaskets and front module O-ring seal. Install new gaskets or O-ring seal if necessary.
^ Clean and inspect the sealing surfaces.