Intake Manifold Replacement
Intake Manifold Replacement
Removal Procedure
1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
3. Release the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement Charge Air Cooler Outlet Pipe Replacement.
4. Relief the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.
Caution:
Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold can be damaged if it is removed when the engine is hot.
Note:
The charger AIR bypass tube assembly connected from the charger AIR bypass valve solenoid to the charger AIR bypass valve tank assembly is permanently attached to the tank assembly. Do not attempt to disconnect the charger AIR bypass tube assembly at the charger AIR bypass valve tank assembly.
5. Disconnect the charger AIR bypass tube assembly from the intake manifold.
6. Disconnect the charger AIR bypass tube with the retaining clip from the charger AIR bypass valve solenoid.
7. Remove the charger AIR bypass valve tank assembly nut (2).
Note:
The charger AIR bypass bolt is captured on the bracket and should not be removed from the bracket. Loosen the bolt only until it is no longer attached to the block when removing the charger AIR bypass valve tank assembly.
8. Loosen the charger AIR bypass valve tank assembly bolt.
9. Remove the charger AIR bypass valve tank assembly (1).
10. Disconnect the remaining charger AIR bypass tubes at the turbocharger and vehicle.
11. Remove the charger AIR bypass valve solenoid bolts.
12. Remove the charger AIR bypass valve solenoid (1).
13. Remove the high pressure fuel pump cover bolts.
14. Remove the high pressure fuel pump cover (2).
15. Remove the high pressure fuel pump noise insulator (1).
Warning
Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.
16. Loosen and disconnect the fuel feed line tube nut (1).
17. Remove the fuel feed line bolts.
18. Remove the fuel feed line (2).
19. Inspect the fuel feed line nut for damaged threads.
20. Inspect the fuel feed line sealing bail for damage or debris.
21. Replace the fuel feed line if any damage is found.
22. Disconnect the rear knock sensor from the intake manifold brace.
23. Remove the intake manifold brace bolt (1) and nut (3).
24. Remove the intake manifold brace (2).
25. Remove the intake manifold bolts and nuts (3).
26. Remove the intake manifold (2).
27. Remove the intake manifold gasket (1).
28. Clean and Inspection intake manifold. Refer to Intake Manifold Cleaning and Inspection (LDK, LHU).
29. Transfer parts as needed.
30. Disconnect electrical connectors as needed.
Installation Procedure
1. Install a NEW intake manifold gasket (1).
2. Install the intake manifold (2).
Caution:
Refer to Fastener Caution Fastener Caution.
3. Install the intake manifold bolts and nuts (3) finger tight.
4. Tighten the intake manifold bolts and nuts in sequence:
1. Tighten the intake manifold bolts to 25 Nm (18 lb ft).
2. Tighten the intake manifold nuts to 22 Nm (16 lb ft).
5. Install the intake manifold brace (2).
6. Install the intake manifold brace bolt (1) and nut (3) and tighten to 25 Nm (18 lb ft).
7. Connect the rear knock sensor to the intake manifold brace.
8. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
9. Install the fuel feed line (2).
10. Install the fuel feed line bolts.
11. Connect the low pressure fuel line nut (1) and tighten to 30 Nm (22 lb ft).
12. Tighten the fuel feed line bolts to 10 Nm (89 lb in).
13. Install the high pressure fuel pump noise insulator (1).
14. Install the high pressure fuel pump cover (2).
15. Install the high pressure fuel pump cover bolts and tighten to 10 Nm (89 lb in).
16. Install the charger AIR bypass valve solenoid (1) with charger AIR bypass tube assemblies.
17. Install the charger AIR bypass valve solenoid bolts and tighten to 10 Nm (89 lb in).
Note:
Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.
18. Connect the charger AIR bypass tube assemblies and clips from the charger AIR bypass valve solenoid to the turbocharger and vehicle.
19. Install the charger AIR bypass valve tank assembly (1).
20. Tighten the charger AIR bypass valve tanks assembly bolt to 25 Nm (18 lb ft).
21. Install the charger AIR bypass valve tank assembly nut (2) and tighten to 25 Nm (18 lb ft).
Note:
Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location. The tube with retaining clamp located on the charger AIR bypass valve tank assembly left side connects to the charger AIR bypass valve solenoid. The right side, permanently attached tube connects to the intake manifold.
22. Connect the appropriate charger AIR bypass tube assembly to the intake manifold.
23. Connect the final charger AIR Bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.
24. Install the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement Charge Air Cooler Outlet Pipe Replacement.
25. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
26. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.