Federal Emissions

Intake Manifold Tube Replacement (Federal Emissions (RPO FE9))

Removal Procedure





1. Remove the turbocharger.
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.
- The fuel junction block.
- The fuel hoses to the fuel injection control module (FICM) and the FICM wiring harness.
- The fuel pipes to the left fuel rail.
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.

Installation Procedure





Notice: Refer to Fastener Notice in Service Precautions.

1. Install the intake air heater, if removed.
- Tighten the intake heater to 50 Nm (37 ft. lbs.).
2. Install the intake manifold tube with NEW gaskets.





3. Install the intake manifold tube bolts and nuts.
- Tighten the bolts and nuts to 10 Nm (89 inch lbs.) in the numerical order.
4. Install the following fuel pipes and wiring harnesses:
- The main fuel pipes.
- The fuel junction block.
- The fuel hoses to the FICM and the FICM wiring harness.
- The fuel pipes to the left fuel rail.
5. Install the intake air heater terminal and nut.
- Tighten the terminal nut to 4 Nm (35 inch lbs.).





6. Install the turbocharger boost sensor with bracket.
7. Install the turbocharger boost sensor bracket bolt.
- Tighten the bolt to 10 Nm (89 inch lbs.).
8. Install the turbocharger.