With Federal Emissions

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution IN SERVICE PRECAUTIONS.

IMPORTANT: The intake air heater relay is a part of the glow plug relay on Federal Emissions vehicles.

1. Remove the negative battery cables.




2. Loosen the outlet duct clamp at the upper intake manifold cover.
3. Remove the upper intake manifold cover from the outlet duct.
4. Remove the upper intake manifold cover.
5. Remove the battery supply wiring harness nut (1) and harness connector (2).
6. Remove the glow plug wiring harness nuts and harness connectors (4,6).




7. Release the wiring harness connectors (3,5) at the glow plug relay (8).
8. Remove the glow plug wiring harness nuts and harness connectors (4,6).
9. Remove the two glow plug relay mounting nuts.
10. Remove the glow plug relay from the mounting studs.

INSTALLATION PROCEDURE




1. Install the glow plug relay on the mounting studs.

NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the glow plug relay mounting nuts.

Tighten
Tighten the nuts to 42 N.m (31 lb ft).

3. Install the wiring harness connector to the relay.
4. Install the glow plug wiring harness and nuts and harness connectors (4,6).

Tighten
Tighten the nuts to 5 N.m (44 lb in).

5. Connect the wiring harness connectors (3,5) at the glow plug relay (8).
6. Install the battery supply wiring harness nut (1) and harness connector (2) on the glow plug relay (8).

Tighten
Tighten the nut to 5 N.m (44 lb in).




7. Install the upper intake manifold cover.
8. Install the upper intake manifold cover to the outlet duct.
9. Tighten the outlet duct clamp at the upper intake manifold cover.

Tighten
Tighten the clamp to 6 N.m (53 lb in).

10. Install the negative battery cables.