Intake Manifold Tube Replacement Federal Emissions (RPO FE9)

1. Remove the turbocharger. Refer to Turbocharger Replacement .
2. Remove the intake air heater nut and wire terminal from the intake air heater.
3. Remove the following fuel pipes and wiring harnesses:

•	The main fuel pipes. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls-6.6 L.

•	The fuel junction block. Refer to Fuel Junction Block Replacement in Engine Controls-6.6 L.

•	The fuel hoses to the fuel injection control module (FICM) and the FICM wiring harness. Refer to Fuel Injector Control Module Replacement in Engine Controls-6.6 L.

•	The fuel pipes to the left fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 2 in Engine Controls-6.6 L.

4. Remove the turbocharger boost sensor bracket bolt.
5. Remove the turbocharger boost sensor with bracket.



6. Remove the intake air heater from the intake manifold tube, if replacing the tube.
7. Remove the intake manifold tube bolts and nuts.
8. Remove the intake manifold tube and the gaskets.
9. Discard the gaskets.
10. Clean the intake manifold tube in cleaning solvent and air dry.

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.

1. Install the intake air heater, if removed.

Tighten
Tighten the intake heater to 50 N·m (37 lb ft).

2. Install the intake manifold tube with NEW gaskets.



3. Install the intake manifold tube bolts and nuts.

Tighten
Tighten the bolts and nuts to 10 N·m (89 lb in) in the numerical order.

4. Install the following fuel pipes and wiring harnesses:

•	The main fuel pipes. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls-6.6 L.

•	The fuel junction block. Refer to Fuel Junction Block Replacement in Engine Controls-6.6 L.

•	The fuel hoses to the FICM and the FICM wiring harness. Refer to Fuel Injector Control Module Replacement in Engine Controls-6.6 L.

•	The fuel pipes to the left fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 2 in Engine Controls-6.6 L.

5. Install the intake air heater terminal and nut.

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




6. Install the turbocharger boost sensor with bracket.
7. Install the turbocharger boost sensor bracket bolt.

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

8. Install the turbocharger. Refer to Turbocharger Replacement .

Intake Manifold Tube Replacement California Emissions (RPO YF5)

1. Remove the turbocharger boost sensor bracket bolt.
2. Remove the turbocharger boost sensor with bracket.
3. Remove the intake air heater nut and wire terminal from the intake air heater.
4. Remove the intake air heater and gasket, if replacing the tube.
5. Remove the following fuel pipes and wiring harnesses:

•	The main fuel pipes. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls-6.6 L.

•	The fuel junction block. Refer to Fuel Junction Block Replacement in Engine Controls-6.6 L.

•	The fuel hoses to the fuel injection control module (FICM) and the FICM wiring harness. Refer to Fuel Injector Control Module Replacement in Engine Controls-6.6 L.

•	The fuel pipes to the left fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 2 in Engine Controls-6.6 L.




6. Remove the exhaust gas recirculation (EGR) cooling hose clamps.
7. Remove the EGR cooling hose.
8. Remove the EGR bolts and nuts.
9. Remove the EGR cooler bracket bolts.
10. Remove the EGR cooler bracket.
11. Remove the EGR and cooler.



12. Remove the intake manifold tube bolts and nuts.
13. Remove the intake manifold tube and the gaskets.
14. Discard the gaskets.
15. Clean the intake manifold tube in cleaning solvent and air dry.

1. Install the intake manifold tube with 2 NEW gaskets.




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 intake manifold tube bolts and nuts.

Tighten
Tighten the bolts and nuts to 9 N·m (80 lb in) in the numerical order.




3. Install the EGR cooler bracket.
4. Install the EGR and cooler.
5. Install the EGR cooler bracket bolts.
6. Install the EGR bolts and nuts.
7. Install the EGR cooling hose.
8. Install the EGR cooling hose clamps.
9. Install the following fuel pipes and wiring harnesses:

•	The main fuel pipes. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls-6.6 L.

•	The fuel junction block. Refer to Fuel Junction Block Replacement in Engine Controls-6.6 L.

•	The fuel hoses to the FICM and the FICM wiring harness. Refer to Fuel Injector Control Module Replacement in Engine Controls-6.6 L.

•	The fuel pipes to the left fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 2 in Engine Controls-6.6 L.




10. Install the intake air heater and gasket, if required.

Tighten
Tighten the intake air heater to 50 N·m (37 lb ft).

11. Install the intake air heater terminal and nut.

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

12. Install the turbocharger boost sensor with bracket.
13. Disconnect the wire terminal to the intake air heater.
14. Install the turbocharger boost sensor bracket bolt.

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