Intake Manifold Replacement Upper

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in Engine Electrical.
2. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
3. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
4. Remove the air intake duct from the upper intake manifold.
5. Remove the transmission oil level indicator tube from the upper intake manifold (if needed).
6. Remove the rear air conditioning line from the upper intake manifold (if equipped).




Important: Do not attempt to remove the upper intake manifold with the lower intake manifold as an assembly. Damage to the intake manifold gaskets, upper intake manifold and the turbocharger may occur during reassembly.

7. Remove the upper intake manifold bolts.



8. Remove the upper intake manifold and gaskets from the lower intake manifold.

Important: Always replace the O-ring between the upper intake manifold and the turbocharger. Coat the new O-ring with clean engine oil before installing on the turbocharger.

1. Install the upper intake manifold to the lower intake manifold and the turbocharger.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the upper intake manifold bolts

Tighten
Tighten the bolts to 23 N·m (17 lb ft).

3. Install the rear A/C line to the upper intake manifold (if equipped).
4. Install the transmission oil level indicator tube to the upper intake manifold (if needed).



5. Install the air intake duct to the turbocharger.
6. install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
7. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
8. Connect the battery cables to the batteries. Refer to Battery Cable Replacement in Engine Electrical.

Intake Manifold Replacement Lower

Important: Do not attempt to remove the upper and lower intake manifold as an assembly from the engine. Damage to the upper and lower intake manifolds as well as the turbocharger could occur upon reinstallation of these components.

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in Engine Electrical.
2. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement .
3. Remove the boost sensor relay. Refer to Boost Sensor Replacement .
4. Remove the glow plug relay. Refer to Glow Plug Relay Replacement .
5. Mark the following components in order to ensure proper reinstallation:

•	The fuel line retaining clips

•	The lower intake manifold studs.

•	The electrical harness retaining clips and ground straps.

6. Remove the lower intake manifold studs and fuel line clips.
7. Remove the lower intake manifold and gaskets from the cylinder heads.

1. Install the lower intake manifold gasket to the cylinder head.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the lower intake manifold bolts to the cylinder head.

Tighten
Tighten the bolts to 42 N·m (31 lb ft).

3. Install the fuel line retaining clips.
4. Install the electrical harness retaining clips and ground straps.
5. Install the glow plug relay to the lower intake manifold. Refer to Glow Plug Relay Replacement .
6. Install the boost sensor relay to the lower intake manifold. Refer to Boost Sensor Replacement
7. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement
8. Connect the battery negative cables to the batteries. Refer to Battery Cable Replacement in Engine Electrical.