Removal

- Tools Required
- J 39664 Manifold Cover Set, or equivalent

1. Disconnect the negative battery cables.
2. Remove the fuel filter.
3. Drain the cooling system.





4. Remove the thermostat bolts.
5. Remove the fuel line return hose and the clips.

NOTE: Mark the placement of the studs in order to properly reInstall them.

6. Remove the Boost solenoids with the bracket from the intake manifold studs.
7. Remove the heater hose bracket.
8. Remove the long pencil brace to the turbocharger.
9. Remove the upper radiator hose.





10. Remove the fuel filter assembly and the POE wiring harness bracket to the rear of the lower intake manifold.
- Tighten the fuel filter mount bolts to 42 Nm (31 lb ft).

NOTE: In order to loosen the sealer, run a small screw driver (flat blade) between the hose and the upper intake manifold. Do not damage the hose.





11. Remove the air intake hose from the turbocharger to the upper intake manifold.

NOTE: Mark the fuel line clips and brackets in order to insure proper reInstallation.

12. Remove the intake manifold studs and fuel line clips.





13. Remove the intake manifold and the gasket.

NOTE: If any further service work is to be done, cover the intake ports with the J 39664.

14. Clean the gasket surfaces on the intake manifold and the cylinder heads.