Removal Procedure
- Remove the turbocharger assembly. Refer to
Turbocharger Replacement
.
- Remove the fuel junction block. Refer to
Fuel Junction Block Replacement
in Engine Controls - 6.6 L.
- Remove the left fuel rail assembly. Refer to
Fuel Injection Fuel Rail Assembly Replacement - Bank 2
in Engine Controls - 6.6 L.
- Remove the intake manifold tube. Refer to
Intake Manifold Tube Replacement
.
- Remove the 9 bolts and
the 2 nuts from the intake manifold.
A bolt is located in the intake manifold opening.
Important: The intake manifold uses sealer. Pry at the area by the common rail
bolt holes. Avoid damage to the sealing surfaces.
- Remove the intake manifold from the cylinder head.
- To prevent entry of debris in the cylinder head, tape the openings.
Inspection and Repair
- Clean the sealant from the intake manifold and the cylinder head
sealing surface.
- Clean the intake manifold in cleaning solvent and air dry.
- Inspect the intake manifold for cracking, distortion, and any
damage.
- Replace the intake manifold if any of the above conditions exist.
Installation Procedure
- Apply a 2-3 mm
(1/8 in) wide to 0.5-1.5 mm (1/16 in) high bead
of sealer GM P/N 12378521 or equivalent to the sealing
surface of the intake manifold.
Important: The left side and the right side intake manifolds are not interchangeable.
- Install the intake manifold 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.
- Install the intake
manifold 9 bolts and 2 nuts.
Tighten
Tighten the intake manifold bolts and nuts to 21 N·m (15 lb ft)
in the sequence shown.
- Install the intake manifold tube. Refer to
Intake Manifold Tube Replacement
.
- Install the left fuel rail assembly. Refer to
Fuel Injection Fuel Rail Assembly Replacement - Bank 2
in Engine Controls - 6.6 L.
- Install the fuel junction block. Refer to
Fuel Junction Block Replacement
in Engine Controls - 6.6 L.
- Install the turbocharger assembly. Refer to
Turbocharger Replacement
.