Intake Manifold

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Drain the cooling system. For additional information, refer to Section 303-03 .

2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .

3. Disconnect the LH turbocharger bypass valve electrical connector.

4. Disconnect the LH turbocharger bypass valve hose from the RH Charge Air Cooler (CAC) tube.

5. NOTE: Mark the location of each hose for installation.

   Disconnect the 3 turbocharger wastegate hoses.

6. Disconnect the RH turbocharger bypass valve electrical connector.

7. Disconnect the RH turbocharger bypass valve hose from the RH turbocharger intake tube.

8. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

   Remove the RH CAC tube nut from the intake manifold.

9. Loosen the clamp for the RH CAC tube.

10. Loosen the clamp and remove the RH CAC tube from the RH turbocharger.

11. Loosen the clamp and position CAC outlet pipe-to-Throttle Body (TB) aside.

12. Disconnect the Throttle Position (TP) sensor and electronic TB electrical connectors.

13. Disconnect the quick connect coupling from the intake manifold. For additional information, refer to Section 310-00 .

14. Disconnect the quick connect coupling Evaporative Emission (EVAP) tube from the intake manifold. For additional information, refer to Section 310-00 .

15. Detach the EVAP purge valve from the intake manifold.

16. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.

17. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information, refer to Section 310-00 .

18. Detach and disconnect the 2 fuel injector wiring harness electrical connectors.

19. Disconnect the Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor electrical connector.

20. Disconnect the turbocharger wastegate regulating valve electrical connector.

21. Detach the 2 wire harness-to-intake manifold retainers.

22. Detach the 2 wire harness retainers from the LH valve cover stud bolt.

23. Detach the 2 wire harness retainers from the LH valve cover.

24. Disconnect the 2 coolant heater hoses from the intake manifold.

25. Disconnect the 2 turbocharger coolant hoses from the intake manifold.

26. Disconnect the lower radiator hose from the thermostat housing.

27. Remove the bolt and ground wire from the engine front cover.

28. Disconnect the upper radiator hose at the intake manifold and position the hose aside.

29. NOTE: Note the routing of the 2 fuel rail wiring harnesses for installation.

    Remove the 12 bolts and the intake manifold.
    • Remove and discard the intake manifold, coolant crossover and thermostat housing gaskets.
    • Clean and inspect all sealing surfaces.

Installation

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   NOTE: Make sure the fuel rail wiring harnesses are routed correctly.

   NOTE: Installing the 2 long bolts first will aid in installing the intake manifold.

   Using new intake manifold, coolant crossover and thermostat housing gaskets, install the intake manifold and the 12 bolts. Tighten in the sequence shown in 2 stages.
   • Stage 1: Tighten to 10 Nm (89 lb-in).
   • Stage 2: Tighten an additional 45 degrees.

2. Connect the upper radiator hose to the intake manifold.

3. Install the ground wire and bolt to the engine front cover.
   • Tighten to 10 Nm (89 lb-in).

4. Connect the lower radiator hose to the thermostat housing.

5. Connect the 2 turbocharger coolant hoses from the intake manifold.

6. Connect the 2 coolant heater hoses from the intake manifold.

7. Attach the 2 wire harness retainers to the LH valve cover.

8. Attach the 2 wire harness retainers to the LH valve cover stud bolt.

9. Attach the 2 wire harness-to-intake manifold retainers.

10. Connect the turbocharger wastegate regulating valve electrical connector.

11. Connect the MAP / IAT2 sensor electrical connector.

12. Connect and attach the 2 fuel injector wiring harness electrical connectors.

13. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to Section 310-00 .

14. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
    • Tighten to 10 Nm (89 lb-in).

15. Attach the EVAP purge valve to the intake manifold.

16. Connect the quick connect coupling EVAP tube to the intake manifold. For additional information, refer to Section 310-00 .

17. Connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00 .

18. Connect the TP sensor and electronic TB electrical connectors.

19. NOTE: Align the index marks for the CAC outlet pipe.

    Position CAC outlet pipe on the TB and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).

20. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube to the RH turbocharger and tighten the clamp.
    • To install, tighten to 5 Nm (44 lb-in).

21. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube and tighten the clamp.
    • To install, tighten to 5 Nm (44 lb-in).

22. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Install the RH CAC tube and the RH CAC tube nut to the intake manifold.
    • Tighten to 6 Nm (53 lb-in).

23. Connect the RH turbocharger bypass valve hose to the RH turbocharger intake tube.

24. Connect the RH turbocharger bypass valve electrical connector.

25. Connect the 3 turbocharger wastegate hoses.

26. Connect the turbocharger wastegate regulating valve hose to the RH CAC tube.

27. Connect the LH turbocharger bypass valve electrical connector and the turbocharger bypass valve hose.

28. Install the ACL outlet pipe. For additional information, refer to Section 303-12 .

29. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .