Intake Manifold Tube Replacement

Intake Manifold Tube Replacement

Removal Procedure

1. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (Service and Repair).




2. Open the intake air heater (IAH) harness lead cover (2).
3. Remove the engine wiring harness lead nut (1) from the IAH stud.
4. Remove the engine wiring harness lead (3) from the IAH stud.




5. Remove the electrical harness bolts (1).
6. Reposition the harness clip from the intake manifold tube, as needed.




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




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




13. If necessary, remove the intake manifold tube.
14. If necessary, remove and discard the 2 O-ring seals from the tube.
15. Clean the gasket surfaces of the exhaust gas recirculation (EGR) cooler tube, intake manifold tube and inlet tube.

Installation Procedure




1. If necessary, install NEW O-ring seals onto the tube.
2. If necessary, install the intake manifold tube.




3. Install the air inlet tube and NEW gaskets.
Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the air inlet tube nuts and bolt.

Tighten the nuts to 25 Nm (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 Nm (89 lb in).




9. Install the electrical harness bolts (1).

Tighten the bolts to 4 Nm (35 lb in).




10. Install the engine wiring harness lead (3) to the IAH stud.
11. Install the engine wiring harness lead nut (1) to the IAH stud.

Tighten the nut to 10 Nm (89 lb in).

12. Close the IAH harness lead cover (2).
13. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (Service and Repair).