Intake Manifold Replacement

Single Use Fasteners and Components Exhaust Gas Recirculation Cooler Inlet Pipe Gasket Exhaust Gas Recirculation Pipe Seal Intake Manifold Gasket [6x] Oil Level Indicator Tube Seal Throttle Body Gasket Removal Procedure

1. Plenum Front Panel Outer Reinforcement » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
2. Drain the cooling system. Cooling System Draining and Filling
3. Front Wheelhouse Liner - Left Side » Remove — Front Wheelhouse Liner Replacement

Intake Manifold Replacement — figure 1

4. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
5. Engine Wiring Harness Bracket (2) » Reposition

Intake Manifold Replacement — figure 2

6. Oil Level Indicator Tube Stud (1) » Remove
7. Clip (2) @ Oil Level Indicator Tube » Remove
8. Oil Filler Cap » Remove

Intake Manifold Replacement — figure 3

9. Intake Manifold Cover Bolt (1) » Remove
10. Intake Manifold Cover (2) » Remove
11. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

Intake Manifold Replacement — figure 4

12. Charge Air Cooler Outlet Air Hose Clamp (1) » Loosen until disengaged [2x]
13. Charge Air Cooler Outlet Air Hose (2) » Remove

Intake Manifold Replacement — figure 5

14. Disconnect the throttle body electrical connector.
15. Throttle Body Bolt (1) » Remove [3x]
16. Throttle Body (2) » Remove
17. Throttle Body Gasket (3) » Remove and DISCARD

Intake Manifold Replacement — figure 6

18. Hood Latch Actuator Bolt (1) » Remove [2x]
19. Hood Secondary Latch Release Handle (2) » Remove

Intake Manifold Replacement — figure 7

20. Intake Air Baffle Retainer (1) » Remove [9x]
21. Intake Air Splash Shield (2) » Remove

Intake Manifold Replacement — figure 8

22. Intake Air Duct Retainer (1) » Remove
23. Intake Air Duct (2) » Reposition

Intake Manifold Replacement — figure 9

24. Air Cleaner Outlet Duct Clamp (1) » Loosen [2x]
25. Air Cleaner Outlet Front Duct (2) » Remove
26. Disconnect the mass airflow sensor electrical connector.

Intake Manifold Replacement — figure 10

27. Air Cleaner Housing Cover Bolt (1) » Remove [3x]
28. Air Cleaner Upper Housing (2) » Remove

Intake Manifold Replacement — figure 11

29. Electrical Connector (1) @ Air Cleaner Lower Housing » Remove
30. Remove all retainers from air cleaner lower housing.

Intake Manifold Replacement — figure 12

31. Engine Wiring Harness Fuse Block Bracket Bolt (1) » Remove
32. Accessory Wiring Junction Block (2) » Reposition

Intake Manifold Replacement — figure 13

33. Air Cleaner Nut (1) » Remove

Intake Manifold Replacement — figure 14

34. Air Cleaner Lower Housing (1) » Remove

Intake Manifold Replacement — figure 15

35. Air Cleaner Outlet Duct Clamp (1) » Loosen
36. Air Cleaner Outlet Duct (2) » Remove

Intake Manifold Replacement — figure 16

37. Unclip the engine coolant temperature sensor wiring harness (1) from the intake manifold.

Intake Manifold Replacement — figure 17

38. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
39. Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose (2) @ Thermostat Bypass Hose » Remove

Intake Manifold Replacement — figure 18

40. Engine Coolant Air Bleed Hose Stud (2) » Remove
41. Thermostat Bypass Hose (1) » Reposition

Intake Manifold Replacement — figure 19

42. Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
43. Turbocharger Coolant Return Hose (2) @ Exhaust Gas Recirculation Coolant Return Pipe » Remove
44. Exhaust Gas Recirculation Coolant Return Pipe (3) @ Exhaust Gas Recirculation Coolant Return Pipe » Remove

Intake Manifold Replacement — figure 20

45. Thermostat Bypass Pipe Bolt (3) » Remove
46. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
47. Wiring Harness Retainer (2) @ Exhaust Gas Recirculation Coolant Return Pipe » Remove
48. Exhaust Gas Recirculation Coolant Return Pipe (4) » Remove

Intake Manifold Replacement — figure 21

49. Disconnect and unclip the glow plug wiring harness (1) from the intake manifold.

Intake Manifold Replacement — figure 22

50. Engine Oil Level Indicator (1) » Remove

Intake Manifold Replacement — figure 23

51. Oil Level Indicator Tube Bolt (1) » Remove

Note

With aid of assistant reposition the engine wiring harness and note the routing of oil level indicator tube.

52. Oil Level Indicator Tube (2) » Remove

Intake Manifold Replacement — figure 24

53. Oil Level Indicator Tube Seal (2) » Remove and DISCARD

Intake Manifold Replacement — figure 25

54. Disconnect the intake air pressure and temperature sensor electrical connector.
55. Intake Air Pressure and Temperature Sensor Bolt (1) » Remove
56. Intake Air Pressure and Temperature Sensor (2) » Remove

Intake Manifold Replacement — figure 26

57. Remove the 3 rear engine wiring harness channel nuts (1).
58. Position the rear engine wiring harness channel (2) out of the way.

Intake Manifold Replacement — figure 27

59. Remove the engine coolant outlet pipe bracket bolt (1) and position the engine coolant air bleed hose (2) out of the way.

Intake Manifold Replacement — figure 28

Note

Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

60. Exhaust Gas Recirculation Cooler Bolt (1) » Remove [2x]

Intake Manifold Replacement — figure 29

61. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
62. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe » Remove
63. Turbocharger Coolant Feed and Return Pipe Bolt (3) » Remove

Intake Manifold Replacement — figure 30

64. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
65. Exhaust Gas Recirculation Outlet Pipe Bolt (2) » Remove

Intake Manifold Replacement — figure 31

66. Exhaust Gas Recirculation Outlet Pipe Bolt (1) » Remove [2x]

Intake Manifold Replacement — figure 32

67. Remove the exhaust gas recirculation pipe (1).
68. Remove and DISCARD the exhaust gas recirculation pipe seal (2).
69. Remove and DISCARD the exhaust gas recirculation cooler inlet pipe gasket (3).

Intake Manifold Replacement — figure 33

70. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
71. Engine Wiring Harness Bracket Bolt (2) » Remove
72. Disconnect electrical connectors as needed, detach retainer at intake manifold and reposition the engine wiring harness channel (3) away from the front of the engine.

Intake Manifold Replacement — figure 34

73. Intake Manifold Insulator Retainer (2) » Remove [2x]
74. Intake Manifold Insulator (1) » Remove

Intake Manifold Replacement — figure 35

75. Intake Manifold Bolt (2) » Remove [9x]
76. Intake Manifold (1) » Remove
77. Intake Manifold Gasket (3) » Remove and DISCARD [6x] Cleaning and Inspection Procedure - Required

Intake Manifold Replacement — figure 36

1. Inspect the charge air cooler outlet air hose (2): 1.1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 1.2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found. 1.3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing. Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Intake Manifold Replacement — figure 37

1. Clean the intake manifold mating surfaces.
2. Inspect the intake manifold (1) for damage.
3. Inspect the intake manifold (1) for cracks and fractures.
4. Inspect all 12 intake runner valves (5) for damage.
5. Clean the throttle body sealing surface (3).
6. Clean the exhaust gas recirculation cooler outlet pipe sealing surface (2).
7. Clean the intake manifold to cylinder head sealing surface (4).
8. Replace the intake manifold (1) as necessary.

Intake Manifold Replacement — figure 38

9. Visually inspect the intake manifold mounting face (1) for cracks, warpage, or damage. If any damage is found replace the intake manifold. An intake manifold face with cracks, warpage or damage may cause an intake leak and may effect diagnostics and system performance. Installation Procedure

10. Intake Manifold Gasket (3) » Install NEW [6x]

11. Intake Manifold (1) » Install

12. Intake Manifold Bolt (2) » Install and hand tighten [9x]

Caution

Refer to Fastener Caution.

4. Intake Manifold Bolt (2) » Tighten in sequence [9x] — Fastener Specifications

5. Intake Manifold Insulator (1) » Install

6. Intake Manifold Insulator Retainer (2) » Install [2x]

7. Position the engine wiring harness channel (3) at the front of the engine, attach retainer at intake manifold, and connect electrical connectors as needed .

8. Engine Wiring Harness Bracket Bolt (2) » Install and tighten — Fastener Specifications

9. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

10. Install a NEW exhaust gas recirculation cooler inlet pipe gasket (3).

11. Install a NEW exhaust gas recirculation pipe seal (2).

12. Install the exhaust gas recirculation pipe (1).

Intake Manifold Replacement — figure 39

Note

Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

13. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

14. Turbocharger Coolant Feed and Return Pipe Bolt (3) » Install and tighten — Fastener Specifications

15. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe » Install

16. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

17. Exhaust Gas Recirculation Outlet Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications.

18. Exhaust Gas Recirculation Outlet Pipe Bolt (2) » Install and tighten — Fastener Specifications

19. Install the turbocharger coolant return hose clip (1).

Note

Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

20. Exhaust Gas Recirculation Cooler Bolt (1) » Install and tighten [2x] — Fastener Specifications.

21. Engine Coolant Air Bleed Hose (2) » Reposition

22. Engine Coolant Outlet Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

23. Install the rear engine wiring harness channel (2).

24. Engine Wiring Harness Bracket Nut (1) » Install and tighten [3x] — Fastener Specifications.

25. Intake Air Pressure and Temperature Sensor (2) » Install

26. Intake Air Pressure and Temperature Sensor Bolt (1) » Install and tighten — Fastener Specifications

27. Connect the intake air pressure and temperature sensor electrical connector.

28. Oil Level Indicator Tube Seal (2) @ Oil Level Indicator Tube » Install NEW

29. Oil Level Indicator Tube (1) @ Lower Crankcase Extension » Install

Note

With aid of assistant reposition the engine wiring harness and note the routing of oil level indicator tube.

30. Oil Level Indicator Tube (2) » Install

31. Oil Level Indicator Tube Bolt (1) » Install and tighten — Fastener Specifications

32. Engine Oil Level Indicator (1) » Install

33. Connect electrical connector and clip the glow plug wiring harness (1) to the intake manifold.

34. Clip the engine coolant temperature sensor wiring harness (1) to the intake manifold.

35. Exhaust Gas Recirculation Coolant Return Pipe (4) » Install

36. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

37. Thermostat Bypass Pipe Bolt (3) » Install and tighten — Fastener Specifications

38. Wiring Harness Retainer (2) @ Exhaust Gas Recirculation Coolant Return Pipe » Install

39. Exhaust Gas Recirculation Coolant Return Pipe (3) @ Exhaust Gas Recirculation Coolant Return Pipe » Install

40. Turbocharger Coolant Return Hose (2) @ Exhaust Gas Recirculation Coolant Return Pipe » Install

41. Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

42. Thermostat Bypass Hose (1) » Install

43. Engine Coolant Air Bleed Hose Stud (2) » Install and tighten — Fastener Specifications

44. Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose (2) @ Thermostat Bypass Hose » Install

45. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

46. Air Cleaner Outlet Duct (2) » Install

47. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

48. Air Cleaner Lower Housing (1) » Install

49. Air Cleaner Nut (1) » Install and tighten — Fastener Specifications

50. Accessory Wiring Junction Block (2) » Install

51. Engine Wiring Harness Fuse Block Bracket Bolt (1) » Install and tighten — Fastener Specifications

52. Electrical Connector (1) @ Air Cleaner Lower Housing » Install

53. Install all retainers to the air cleaner lower housing.

54. Air Cleaner Upper Housing (2) » Install

55. Air Cleaner Housing Cover Bolt (1) » Install and tighten [3x] — Fastener Specifications

56. Connect the mass airflow sensor electrical connector.

57. Intake Air Duct (2) » Install

58. Intake Air Duct Retainer (1) » Install

59. Intake Air Splash Shield (2) » Install

60. Intake Air Baffle Retainer (1) » Install [9x]

61. Hood Secondary Latch Release Handle (2) » Install

62. Hood Latch Actuator Bolt (1) » Install and tighten [2x] — Fastener Specifications

63. Throttle Body Gasket (3) » Install NEW

64. Throttle Body (2) » Install

65. Throttle Body Bolt (1) » Install and tighten [3x] — Fastener Specifications

66. Connect the throttle body electrical connector.

67. Charge Air Cooler Outlet Air Hose (2) » Install

68. Charge Air Cooler Outlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

69. Clip (2) @ Oil Level Indicator Tube » Install

70. Oil Level Indicator Tube Stud (1) » Install and tighten — Fastener Specifications

71. Engine Wiring Harness Bracket (2) » Install

72. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

73. Front Wheelhouse Liner - Left Side » Install — Front Wheelhouse Liner Replacement

74. Plenum Front Panel Outer Reinforcement » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

75. Oil Filler Cap » Remove

76. Intake Manifold Cover (2) » Install

77. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

78. Oil Filler Cap » Install

79. Fill the cooling system to the proper level. Cooling System Draining and Filling

80. Start the engine and check for coolant leaks.