EXHAUST
SYSTEM
Ail
INTAKE
MANIFOLD
11
-
3
Fig.
7
Charge
Mir
Temperature Sensor
and
Mir
Temperature Switch
INSTALLATION
(1)
Using
a
new
gasket,
install
the intake
manifold
cover (Fig. 8).
(2)
Install
the
fuel
heater
ground
wire
(Fig.
8).
Tighten
the
bolt
to 12 N-m (110 in. lbs.) torque.
(3)
Connect
the air
temperature switch
to the
in-
take
manifold
cover (Fig. 7).
(4)
Connect
the
charge
air
temperature
sensor
to
the intake
manifold
cover (Fig. 7).
(5)
Some
of
-
the intake
manifold
bolt
holes
are
drilled
through and must be
sealed.
Apply
liquid
te-
flon
sealant
to
the bolts.
Install
the intake
manifold
cover bolts. Tighten the bolts
to
24 N-m (18 ft. lbs.)
torque.
(6)
Install
a new
gasket
between
the air
intake
heater
and the intake
manifold
cover
(Fig.
6).
Install
a new
gasket
on
top
of the air intake
heater
(Fig.
6).
(7)
Install
the air
inlet
tube (Fig. 5). Tighten
the
air
inlet
tube bolts
to
24
N*m
(18 ft. lbs.) torque.
(8)
Connect the intake
manifold
heater
ground
wire
(Fig.
5).
MANIFOLD
FUEL HEATER
INTAKE
GROUND
WIRE
Fig.
8
Manifold Intake Cower
and
Fuel
Heater
Ground
Wire
(9)
Install
and tighten the air intake
heater
power
supply
nuts
to
14 Nrn (10 ft. lbs.) torque.
(10)
Position the intercooler outlet duct onto the air
inlet
tube
(Fig.
5). Tighten the intercooler outlet duct
clamps to
8
Nun (72 in. lbs.) torque.
(11)
Install
and bleed the
high
pressure
fuel
lines.
Tighten
the
high
pressure
fuel
line
nuts
to 24
Nun
(18 ft. lbs.) torque.
TURBOCHARGER
REMOVAL
.
(1) Disconnect the battery negative cables.
(2)
Disconnect the air intake pipe and exhaust pipe
(Fig.
9).
Fig.
9 Air
Intake
Pipe,
Exhaust
Pipe
and
Turbocharger
(3)
Remove the oil drain tube bolts.
(4)
Remove the oil supply
line
(Fig. 10).
(5)
Disconnect
the
intercooler
inlet
duct
from
the
turbocharger (Fig. 10).
(6)
Remove
the
turbocharger mounting nuts
and
the turbocharger.
(7)
If the turbocharger
is
not to be installed imme-
diately,
cover
the
opening
to
prevent material
from
falling
into the
manifold.
(8)
Clean and inspect the sealing surface.
DISASSEMBLY
(1)
Scribe the housing so they can be assembled in
the
same
position.
(2)
Clamp the turbocharger in
a
bench vise.
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