Removal Procedure
- Loosen the clamp at the upper intake manifold cover.
- Remove the upper intake manifold cover from the outlet duct.
- Remove the upper intake manifold cover.
- If removing the right side, loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
- Remove the outlet duct from the turbocharger and the MAT/IAT sensor.
- In order to access the right side, loosen both charged air cooler outlet duct to intake manifold duct hose clamps.
- Remove the charged air cooler outlet duct to intake hose.
- In order to access the left side, loosen the charged air cooler inlet duct to turbocharger clamp.
- Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.
- Remove the heater outlet hose bracket nut (1).
- Remove the heater outlet hose bracket bolt (2).
- Move the heater hose out of the way.
- Disconnect both of the positive crankcase ventilation (PCV) hoses from the valve rocker arm covers.
- Disconnect the oil separator oil drain hose form the engine block.
- Remove the oil separator and hoses.
- Inspect the all of the PCV hoses for damage.
- Inspect the oil separator for cracks or damage.
- Replace any parts found with damage.
Important: After removing the turbocharger air ducts and hoses, cover the turbocharger openings and the ducts with tape to prevent entry of objects.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
Installation Procedure
- Connect the oil separator oil drain hose to the engine block.
- Connect both of the PCV hoses to the valve rocker arm covers.
- Position the heater hose.
- Install the heater outlet hose bracket nut (1).
- Install the bolt (2) retaining the heater outlet hose to the generator bracket.
- Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.
- Position the clamp as shown for proper clearance.
- Install the charged air cooler outlet duct to intake manifold duct hose.
- Position the clamps as shown for proper clearance.
- Install the outlet duct to the turbocharger.
- Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
- Install the outlet duct to the MAF/IAT sensor.
- Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor
- Install the upper intake manifold cover.
- Install the upper intake manifold cover to the outlet duct.
- Tighten the outlet duct clamp at the upper intake manifold cover.
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.
Tighten
Tighten the nut to 9 N·m (80 lb in).
Tighten
Tighten the heater hose bracket bolt to 25 N·m (18 lb ft).
Tighten
Tighten the clamp to 6 N·m (53 lb in).
The hose is marked DUCT which connects to the charged air cooler outlet duct.
The hose is marked ENG which connects to the intake manifold duct.
Align the marks on the hose with the alignment marks on the pipe and duct.
Tighten
Tighten the clamps to 6 N·m (53 lb in).
Important: The outlet duct must be fully seated against the positive stop feature on the turbocharger inlet.
Important: The outlet duct must be fully seated against the MAF/IAT sensor with the edge of the seal in the vertical position.
Tighten
Tighten the clamps to 6 N·m (53 lb in).
Tighten
Tighten the clamps to 6 N·m (53 lb in).
