Lower Intake Manifold Replacement

Lower Intake Manifold Replacement

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure




1. Remove the upper intake manifold.
2. Remove the drive belt tensioner.
3. Remove the generator rear brace bolt and nut.
4. Remove the generator rear brace.




5. Remove the exhaust gas recirculation (EGR) valve outlet pipe bolt and nut.
6. Remove the EGR valve outlet pipe.




7. Using the J 38185 reposition the hose clamp at the thermostat housing.
8. Remove the radiator inlet hose from the thermostat housing.




9. Remove the generator brace bracket bolts.
10. Remove the generator brace bracket and spacer.




11. Remove the lower intake manifold bolts.
12. Remove the lower intake manifold.




13. Remove the lower intake manifold seals.




14. Remove the lower intake manifold gaskets.




15. If replacing the lower intake manifold perform the following steps, otherwise proceed to step 5 in the installation procedure.
16. Remove the engine coolant temperature (ECT) sensor.




17. Remove the thermostat housing bolt and stud.
18. Remove the thermostat housing and thermostat.

Installation Procedure




1. If replacing the lower intake manifold perform the following steps, otherwise proceed to step 5.
2. Install the thermostat and housing.

Notice: Refer to Fastener Notice.

3. Remove the thermostat housing bolt and stud.

Tighten the bolt/stud to 25 N.m (18 lb ft).




4. Install the ECT sensor.

Tighten the sensor to 23 N.m (17 lb ft).




5. Clean the lower intake manifold sealing surface prior to installing the seals or gaskets. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
6. Install the lower intake manifold gaskets.




7. Apply sealer to the ends of the intake manifold seals. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
8. Install the lower intake manifold seals.




9. Install the lower intake manifold.
10. Apply threadlock to the lower intake manifold bolt threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
11. Install the lower intake manifold bolts.

Tighten the bolts to 15 N.m (11 lb ft).




12. Install the generator brace bracket and spacer.
13. Install the generator brace bracket bolts.

Tighten the bolts to 50 N.m (37 lb ft).




14. Install the radiator inlet hose to the thermostat housing.
15. Using the J 38185 position the hose clamp at the thermostat housing.




16. Install the EGR valve outlet pipe.
17. Install the EGR valve outlet pipe bolt and nut.

Tighten the bolt/nut to 25 N.m (18 lb ft).




18. Install the generator rear brace.
19. Install the generator rear brace bolt and nut.

Tighten the bolt/nut to 50 N.m (37 lb ft).

20. Install the drive belt tensioner.
21. Install the upper intake manifold.