Intake Manifold Replacement Upper

1. Disconnect the battery negative cables from the batteries. Refer to Battery Cable in Engine Electrical.
2. Remove the upper intake manifold cover.
3. Remove the air intake duct from the upper intake manifold.
4. Loosen the clamps on the hose between the turbocharger and the upper intake manifold. Refer to Turbocharger .

Important: In order to loosen the sealer, run a small screw driver (flat blade) between the hose and the upper intake manifold. Use caution as not to damage the hose.

5. Loosen the hose connecting the upper intake manifold and the turbocharger.
6. Slide the hose connecting the upper intake manifold and the turbocharger on to the upper intake manifold.



7. Remove the EGR Valve (L 56 only) from the upper intake manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls-6.5L.



8. Remove the brace (long for the L 65 and short for the L 56) from the turbocharger to the upper intake manifold.



9. Remove the upper intake manifold bolts from the lower intake manifold (L 65 shown).
10. Remove the upper intake manifold and the gasket from the lower intake manifold.

Important: When replacing the upper intake manifold gasket for the L 56, always replace the O-ring between the upper and lower intake manifolds. Failure to replace this O-ring will cause a driveability problem.

1. Install the upper intake manifold to the lower 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.

2. Install the mounting bolts.

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

3. Install the EGR valve (L 56) to the upper intake manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls-6.5L.
4. Install the air intake duct to the upper intake manifold.



5. Install the upper intake manifold cover.

Tighten
Tighten the bolts to 12N·m (106 lb in).

Important: Apply a small amount of silicone sealant on the openings of the hose before installing it on the turbocharger and the upper intake manifold.

6. Slide the hose connecting from the upper intake manifold on to the turbocharger.
7. Tighten the clamps on the hose between the turbocharger and the upper intake manifold. Refer to Turbocharger .



8. Install the brace (long for the L 65 and short for the L 56) from the turbocharger to the upper intake manifold.
9. Connect the battery negative cables to the batteries. Refer to Battery Cable in Engine Electrical.

Intake Manifold Replacement Lower

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable in Engine Electrical.
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 Control-6.5L.
4. Remove the EGR/Boost solenoids (L 56 only) with the bracket from the intake manifold studs. Refer to Exhaust Gas Recirculation Solenoid Replacement .
5. Remove the Boost solenoids (L 65 only) with brackets from the Intake Manifold studs. Refer to Boost Sensor Replacement .
6. Remove the lower intake manifold stud/bolts from the engine block.
7. Remove the lower intake manifold and the gasket from the engine block.
8. Clean and check the sealing surfaces of the engine block.

Important: Be sure to use the correct gasket. The gasket for the L 56 models have openings for the EGR Valve, the gaskets for the L 65 models do not have openings.

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




Important: There are four stud/bolts, numbers 9,  11, 13,  and 15 exposed to the crankcase, and should be sealed with Teflon sealer. Apply threadlocker GM P/N 12345493 to the threads of 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. Install the lower intake manifold bolts to the cylinder head.

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

4. Install the EGR/Boost solenoids (L 56 only) with the bracket to the intake manifold studs. Refer to Exhaust Gas Recirculation Solenoid Replacement in Engine Controls-6.5L.

Install the Boost solenoids (L 65 only) with brackets to the intake manifold studs. Refer to Boost Sensor Replacement in Engine Controls-6.5L.

5. Install the fuel filter to the lower intake manifold. Refer to Fuel Manager/Filter Replacement in Engine Controls 6.5L.
6. Install the upper intake manifold (L 56 shown) to the lower intake. Refer to Intake Manifold Replacement .
7. Connect the battery negative cable to the battery. Refer to Battery Cable in Engine Electrical.