Intake Air Heater: Service and Repair

INTAKE AIR HEATER (IAH) REPLACEMENT

REMOVAL PROCEDURE




1. Remove the intake manifold cover.
2. Remove the air cleaner outlet duct.
3. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
4. Remove the charged air cooler outlet duct from the intake.




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




7. Remove the engine harness power lead nut (2) from the intake air heater stud.
8. Remove the engine harness power lead (1) from the intake air heater stud.




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




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




15. Remove the intake air heater bolts.
16. Separate the air inlet tube from the intake air heater.

INSTALLATION PROCEDURE




1. Install the air inlet tubes to the intake air heater.

NOTE: Refer to Fastener Notice.

2. Install the intake air heater bolts.

Tighten the bolts to 20 N.m (15 lb ft).




3. Install the air inlet tube and NEW gaskets.
4. Install the air inlet tube nuts.

Tighten the nuts to 25 N.m (18 lb ft).

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 N.m (89 lb in).




9. Install the engine harness power lead (1) to the intake air heater stud.
10. Install the engine harness power lead nut (2) to the intake air heater stud.

Tighten the nut to 10 N.m (89 lb in).




11. Install the electrical harness bolts.

Tighten the bolts to 4 N.m (35 lb in).




12. Install a NEW quick connect fitting clip to the charged air cooler duct.
13. Install the charged air cooler outlet duct to the intake.
14. Install the air cleaner outlet duct.
15. Install the intake manifold cover.