Intake Manifold Tube Replacement LMM

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
3. Remove the right charge air cooler pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement .
4. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
5. Disconnect the engine harness electrical connector (2) from the intake air heater (IAH).
6. Disconnect the engine harness electrical connector (3) from the intake air valve.
7. Remove the 2 engine harness clamp bolts (4).



8. Remove the front intake manifold tube bolt.
9. Reposition the positive battery cable boot.
10. Remove the positive battery cable nut at the IAH.
11. Remove the positive battery cable from the IAH stud.



12. Remove the harness retainer bolt.
13. Remove the 2 front intake manifold tube nuts.
14. Remove the front intake manifold tube bolt.



15. Remove the rear intake manifold tube bolt and 2 nuts.



16. Remove the intake manifold tube.
17. Remove and discard the 2 metal EGR gaskets from the EGR valve.
18. Remove and discard the steel gasket from the center intake manifold.



19. If necessary, remove the lower intake manifold tube.
20. If replacing the intake manifold tube perform the following steps, otherwise proceed to step 5 in the installation procedure.
21. Remove the MAP sensor bolt (1).
22. Remove the MAP sensor (2) and bracket (3).



23. Remove the air intake valve bolts (1).
24. Remove the air intake valve (2) and the IAH (3) from the intake manifold tube.

1. Position the IAH (3) and the air intake valve (2) to the intake manifold tube.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the air intake valve bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




3. Install the MAP sensor (2) and bracket (3).
4. Install the MAP sensor bolt (1).

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




5. Install a NEW steel gasket onto the center intake manifold.
6. Install NEW metal EGR gaskets onto the EGR valve.
7. Install the intake manifold tube.



8. Install the rear intake manifold tube nuts and bolt.

Tighten
Tighten the bolt/nut to 25 N·m (18 lb ft).




9. Install the front intake manifold tube bolt.

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

10. Install the 2 front intake manifold tube nuts.

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




11. Install the front intake manifold tube bolt.

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




12. Connect the engine harness electrical connector (3) to the intake air valve.
13. Connect the engine harness electrical connector (2) to the IAH.
14. Connect the engine harness electrical connector (1) to the MAP sensor.
15. Install the 2 engine harness clamp bolts (4).

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

16. Install the right charge air cooler pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement .
17. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Intake Manifold Tube Replacement LBZ, LLY

1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
2. 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.
3. Remove the charged air cooler outlet duct from the intake.



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



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



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



12. If necessary, remove the intake manifold tube.
13. If necessary, remove and discard the 2 O-ring seals from the tube.
14. 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 .