Intake Manifold Tube Replacement LBZ, LLY

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
3. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
4. Remove the charged air cooler outlet duct from the intake.



5. Remove the electrical harness bolts.
6. Reposition the harness clip from the intake manifold tube, as needed.



7. Remove the air inlet tube to intake manifold tube bolt and nut.



8. Disconnect the intake air heater electrical connector.
9. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
10. Remove the engine harness clip from the air inlet tube.
11. Remove the air inlet tube nuts.
12. Remove the air inlet tube.



13. If necessary, remove the intake manifold tube.
14. If necessary, remove and discard the 2 O-ring seals from the tube.
15. Clean the gasket surfaces of the exhaust gas recirculation (EGR) cooler tube, intake manifold tube and inlet tube.

1. If necessary, install NEW O-ring seals onto the tube.
2. If necessary, install the intake manifold tube.

Notice: Refer to Fastener Notice in the Preface section.




3. Install the air inlet tube and NEW gaskets.
4. Install the air inlet tube nuts.

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

5. Connect the intake air heater electrical connector.
6. Connect the MAP sensor electrical connector.
7. Install the engine harness clip to the air inlet tube.



8. Install the air inlet tube to intake manifold tube bolt and nut.

Tighten
Tighten the bolt/nut to 10 N·m (89 lb in).




9. Install the electrical harness bolts.

Tighten
Tighten the bolts to 4 N·m (35 lb in).




10. Install a NEW quick connect fitting clip to the charged air cooler duct.
11. Install the charged air cooler outlet duct to the intake.
12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
13. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .