Intake Manifold Replacement Upper

1. Remove the intake air temperature (IAT) sensor. Refer to Intake Air Temperature Sensor Replacement in Engine Controls.



2. Remove the boost sensor. Refer to Boost Sensor Replacement in Engine Controls.



3. Remove the retaining bolts from the turbocharger short brace.
4. Remove the turbocharger short brace.
5. Remove the retaining bolt from the turbocharger long brace.
6. Remove the retaining nut from the turbocharger long brace.
7. Remove the turbocharger long brace.



8. Loosen the hose clamps on the turbocharger connection hose.
9. Loosen the turbocharger connection hose.

9.1.	Insert a small, flat screwdriver blade between the turbocharger connection hose and the turbocharger. Slide the screwdriver blade along the surface of the turbocharger until the hose twists freely.

9.2.	Insert a small flat screwdriver blade between the turbocharger connection hose and the upper intake manifold. Slide the screwdriver blade along the surface of the turbocharger until the hose twists freely.




10. Remove the retaining bolts from the upper intake manifold.
11. Remove the upper intake manifold.
12. Remove the gasket.

1. Apply silicone sealant GM P/N 9985943, or equivalent to the turbocharger outlet.
2. Slide the upper intake manifold into the turbocharger outlet hose.
3. Install the intake manifold gasket.
4. Install the upper intake manifold.

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.

5. Install the intake manifold bolts.

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




6. Install the clamps on the turbocharger connector hose.

Tighten
Tighten the connector hose clamps to 6 N·m (50 lb in).




7. Install the turbocharger long brace.
8. Install the retaining nut to the turbocharger long brace.

Tighten
Tighten the nut to 34 N·m (25 lb ft).

9. Install the retaining bolt to the turbocharger long brace.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

10. Install the turbocharger short brace.
11. Install the retaining bolts to the turbocharger short brace.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




12. Install the boost sensor. Refer to Boost Sensor Replacement in Engine Controls.



13. Install the IAT sensor. Refer to Intake Air Temperature Sensor Replacement in Engine Controls.

Intake Manifold Replacement Lower

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.



2. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement .



3. Remove the fuel filter from the lower intake manifold. Refer to Fuel Manager/Filter Replacement in Engine Controls.
4. Remove the glow plug relay. Refer to Glow Plug Relay Replacement in Engine Controls.



5. Remove the wastegate solenoid. Refer to Wastegate Solenoid Replacement in Engine Controls.
6. Remove the valve tube from the crankcase depression regulator.

Tighten
Tighten the bolt/nut to 42 N·m (31 lb ft).




7. Remove the mounting bracket retaining nut from the turbocharger oil feed line.
8. Remove the mounting bracket from the turbocharger oil feed line.

Asperity the components by gently pulling the bracket from the turbocharger oil feed line at a 45 degree angle.




9. Remove the stud/bolts from the lower intake manifold.
10. Remove the lower intake manifold and the gasket from the engine block.
11. Clean and inspect the sealing surfaces of the engine block. Refer to Engine Block Clean and Inspect .

1. Install the lower intake manifold gasket to the cylinder heads.
2. Install the lower intake manifold to the cylinder heads. Refer to Intake Manifold Installation .



3. Install the mounting bracket to the turbocharger oil feed line.

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.

4. Install the mounting bracket retaining nut.

Tighten
Tighten the nut to 25 N·m (18 lb ft).




5. Install the wastegate solenoid to the intake manifold studs. Refer to Wastegate Solenoid Replacement in Engine Controls.
6. Install the bolt/nut to the crankcase depression regulator valve tube.

Tighten
Tighten the bolt/nut to 42 N·m (31 lb ft).

7. Install the glow plug relay. Refer to Glow Plug Relay Replacement in Engine Controls.



8. Install the fuel filter to the lower intake manifold. Refer to Fuel Manager/Filter Replacement in Engine Controls.



9. Install the upper intake manifold to the lower intake. Refer to Intake Manifold Replacement .
10. Connect the negative battery cable.

Intake Manifold Replacement L-57

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable from the battery.



2. Remove the air cleaner assembly from the intake manifold. Refer to Air Cleaner Element Replacement in Engine Controls.



3. Remove the fuel filter from the intake manifold. Refer to Fuel Manager/Filter Replacement in Engine Controls 6.5L.



4. Remove the intake manifold bolts from the intake manifold.



5. Remove the intake manifold and gasket from the cylinder head.
6. Clean and inspect the sealing surfaces of the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

1. Install the intake manifold and gasket to the cylinder heads.



2. Install the intake manifold bolts to the cylinder heads.




Important: There are four stud/bolts numbers 9, 11, 13, and 15 exposed to the crankcase, which should be sealed with Teflon ™ sealer. Apply threadlocker GM P/N 12345493 to the threads of the bolts and studs numbers 1 through 8 and 10, 12, 14, and 16.

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.

3. Tighten the intake manifold bolts in sequence.

Tighten
Tighten the stud/bolts in sequence to 42 N·m (31 lb ft).




4. Install the fuel filter to the intake manifold. Refer to Fuel Manager/Filter Replacement in Engine Controls.



5. Install the air cleaner assembly to the intake manifold. Refer to Air Cleaner Element Replacement in Engine Controls.
6. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement .