Removal Procedure
- Tilt the cab. Refer to Cab Tilting in General Information.
- Disconnect the negative battery cable.
- Remove the air inlet pipes and brackets.
- Remove the coolant overflow hose bracket from the intake manifold.
- Remove the fuel lines from the common rail to the fuel injector.
- Remove the fuel lines from the supply pump to the common rail.
- Remove the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
- Remove the fuel filter and bracket from the intake manifold.
- Remove the intake manifold bolts.
- Remove the intake manifold and gasket.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
Important: Do not bend the fuel injector lines in any shape or form to ease the removal of the intake manifold.
Installation Procedure
- Install the intake manifold and gasket.
- Install the intake manifold bolts.
- Install the common fuel rail.
- Install the fuel lines from the supply pump to the common rail.
- Install the fuel lines from the common rail to the fuel injector.
- Install the fuel injector return line from the fuel injector, fuel common rail and the fuel supply pump.
- Install the fuel filter and the bracket to the intake manifold.
- Install the fuel lines to the fuel filter and to the fuel supply pump.
- Connect the negative battery cable.
- Lower the cab.
Important: Inspect the intake manifold for cracks or damage to the gasket mating surface.
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 intake manifold bolts to 15 N·m (130 lb in).
