Removal

Intake Manifold





Material

Removal
All vehicles
1. Remove the auxiliary battery.
2. Remove the cooling fan stator-6.0L diesel engine.
3. Remove the degas bottle.





4. Remove the upper radiator hose.





5. NOTE: Engine side shown, charge air cooler side similar.

Remove the turbocharger-to-charge air cooler duct.

Vehicles with dual generators





6. Remove the accessory drive belt.





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





8. Remove the accessory drive belt.





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





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





11. Disconnect the wire retainer, generator electrical connector and B+ wire.





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

Vehicles with single generator





13. Remove the accessory drive belt.

All vehicles





14. Position the boot back and disconnect the generator B+ wire and electrical connector.





15. Remove the three bolts and the generator.
16. Remove the turbocharger and the turbocharger pedestal.





17. NOTE: Engine side shown, charge air cooler side similar.

Loosen the clamps and remove the charge air cooler duct.





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





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





20. Disconnect the engine coolant vent hose.
21. Remove the fuel injector control module.





22. Remove the top two bolts from the Injector Pressure Regulator (IPR) heat shield.





23. Remove or position aside the heat insulating wrap. Disconnect the wiring retainer and the Injection Pressure Regulator (IPR) 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. If equipped, disconnect the Exhaust Gas Recirculation (EGR) throttle position control module electrical connector.





28. If equipped, disconnect the EGR throttle position sensor electrical connector.





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





30. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.





31. Disconnect the exhaust pressure sensor electrical connector.





32. NOTE: LH side shown, RH side similar.

Disconnect the eight fuel injectors electrical connectors. Remove the nut and the fuel injector wiring harness.





33. NOTE: It is necessary to remove the fuel filter and drain the housing.

Disconnect the fuel line fittings.
^ Remove and discard the sealing washers.





34. NOTE: It is necessary to remove the oil filter and drain the housing.

Remove the four bolts and the oil filter housing.





35. Remove the bolt and the oil filter return tube.





36. Remove the fuel line.
^ Remove the bolt and the banjo fitting from the fuel line.
^ Discard the sealing washers and remove the fuel line.





37. 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.





38. NOTE: LH shown, RH similar.

Loosen the nuts and bolts from the turbocharger adapter pipe.





39. If equipped, remove the nuts and the turbocharger heat shield.





40. Loosen the EGR cooler V-clamp.





41. NOTE: Keep the EGR cooler V-clamp with the turbo adapter pipe.

Remove the bolts and the intake manifold.





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