Intake manifold – removal and installation
Warning: Diesel fuel is flammable, so take extra precautions when you work on any part of the fuel system. Don’t smoke or allow open flames or bare light bulbs near the work area, and don’t work in a garage where a gas-type appliance (such as a water heater or a clothes dryer) is present. Since diesel fuel is carcinogenic, wear fuel-resistant gloves when there’s a possibility of being exposed to fuel, and, if you spill any fuel on your skin, rinse it off immediately with soap and water. Mop up any spills immediately and do not store diesel fuel-soaked rags where they could ignite. When you perform any kind of work on the fuel system, wear safety glasses and have a Class B type fire extinguisher on hand.
1. Disconnect the cables from the negative terminals of the batteries (see Engine electrical systems).
2. Disconnect the wiring from the EGR temperature sensor and valve actuator.
3. Unbolt the oil dipstick tube.
4. Remove the intercooler tube (see illustration).
6.4 Loosen this clamp attaching the intercooler duct to the air intake housing
5. Remove the clamps from both ends of the air transfer tube. Remove the bolt from the P-clip for the air conditioning line, then remove the air transfer tube.
6. Remove the six air intake screws, then remove the air intake.
7. Clean debris from both ends of all of the fuel tubes.
8. Loosen the two bolts of the bracket at the rear of the head that holds the injector tubes. Tilt the bracket for access to the rear injector tube.
9. Place rags to absorb spilled fuel, then disconnect the rear four injector tubes and remove them. Caution: Don’t bend the lines or allow fuel to run down the sides of the engine.
10. Disconnect the wiring from the sensor at the rear of the fuel rail.
11. Detach the fuel rail from the dump/overflow valve, then remove it.
12. Detach the remaining interfering wiring connections.
13. Remove the intake manifold bolts and lift off the manifold.
14. Installation is the reverse of removal. Use a new gasket. Tighten the intake manifold cover bolts to the torque listed in this Chapter’s Specifications.