Intake Manifold Replacement Without CTF

1. Tilt the cab. Refer to Cab Tilting in General Information.
2. Remove the charge air cooler pipe from the intake pipe.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

3. Disconnect the negative battery cable.
4. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
5. Disconnect the air temperature sensor connector.

Important: Do not bend the fuel injector lines in any shape or form to ease the removal of the intake manifold.

6. Remove the fuel lines from the common rail to the fuel injector.
7. Remove the fuel lines from the supply pump to the common rail.
8. Remove the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
9. Remove the fuel filter and bracket from the intake manifold.
10. Remove the intake manifold bolts.
11. Remove the intake manifold and gasket.

Important: Inspect the intake manifold for cracks or damage to the gasket mating surface.

1. Install the intake manifold and gasket.
2. Install the intake manifold bolts.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the common fuel rail.

Tighten
Tighten the intake manifold bolts to 15 N·m  (11 lb ft).

4. Install the fuel lines from the supply pump to the common rail.
5. Install the fuel lines from the common rail to the fuel injector.
6. Install the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
7. Install the fuel filter and the bracket to the intake manifold.
8. Install the fuel lines to the fuel filter and to the fuel supply pump.
9. Connect the negative battery cable.
10. Install the charge air cooler pipe.
11. Lower the cab.

Intake Manifold Replacement With CTF

1. Tilt the cab. Refer to Cab Tilting in General Information.
2. Remove the charge air cooler pipe from the intake pipe.
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
4. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
5. Disconnect the air temperature sensor connector.
6. Remove the exhaust gas recirculation (EGR) valve. Refer Exhaust Gas Recirculation Valve Replacement in Engine Controls - 7.8L.

Important: Do not bend the fuel injector lines in any shape or form to ease the removal of the intake manifold.

7. Remove the fuel lines from the common rail to the fuel injector.
8. Remove the fuel lines from the supply pump to the common rail.
9. Remove the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
10. Remove the fuel filter and bracket from the intake manifold. Refer to Fuel Filter Replacement in Engine Controls - 7.8L.
11. Remove the intake manifold bolts.
12. Remove the intake manifold and gasket.

Important: Inspect the intake manifold for cracks or damage to the gasket mating surface.

1. Install the intake manifold and gasket.
2. Install the intake manifold bolts.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the common fuel rail.

Tighten
Tighten the intake manifold bolts to 15 N·m  (11 lb ft).

4. Install the fuel lines from the supply pump to the common rail.
5. Install the fuel lines from the common rail to the fuel injector.
6. Install the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
7. Install the fuel filter and the bracket to the intake manifold. Refer to Fuel Filter Replacement in Engine Controls - 7.8L.
8. Connect the MAP sensor.
9. Connect the air temperature sensor.
10. Install the EGR valve . Refer Exhaust Gas Recirculation Valve Replacement in Engine Controls - 7.8L.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
12. Install the charge air cooler pipe.
13. Lower the cab.