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Intake Manifold Removal on Dodge Diesel Engines?

The diesel Engine Intake Manifold Replacing Procedure.

The details are for Dodge Ram Truck.
The procedure Covers Following Engine Models:---

5.9L and 6.7L Engine Models.

5.9L Engines Intake Manifold Removal:----
  1. Disconnect the negative battery cable.
  2. Remove the charge air cooler outlet tube from the air inlet housing.
  3. Remove the engine oil dipstick tube mounting bolt.
  4. Remove dipstick support at fuel filter housing. Position dipstick tube to the side.
  5. Disconnect the air grid heater power cables at the cable mounting studs.
  6. Remove the engine wiring harness connections at the air inlet housing elbow.
  7. Remove the four air inlet housing mounting bolts and remove the housing from top of the heater elements.
  8. Remove the intake air grid heater from the manifold. 

    image
    Fig. Intake air grid heater (1), gasket (2)
  9. Remove the high pressure fuel lines and fuel rail.
  10. Disconnect manifold air temperature/pressure sensor connector.
  11. Remove the remaining intake manifold cover-to-cylinder head bolts.
  12. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air intake.
  13. Clean the intake manifold cover and cylinder head sealing surface.
To install:
  1. Using a new gasket, install the intake manifold cover.
  2. Install the cover-to-cylinder head bolts that do not hold down the fuel rail. Tighten the bolts to 18 ft. lbs. (24 Nm).
  3. Install the high pressure rail and fuel lines
  4. Using two new gaskets, install the intake air grid heater and air inlet housing.
  5. Connect the manifold air temperature/pressure sensor connector.
  6. Install and tighten the air intake heater power supply nut to 120 inch lbs. (14 Nm).
  7. Install oil dipstick tube support at fuel filter housing.
  8. Install the engine oil dipstick tube and mounting bolt.
  9. Position the charge air cooler outlet tube onto the air inlet housing. Tighten the clamps to 100 inch lbs. (11 Nm).
  10. Attach the engine wire harness to the air inlet housing.
  11. Prime the fuel system. Refer to the fuel priming procedure.
  12. Connect the battery negative cables.
6.7L Diesel Engines Intake Manifold Replacing Procedure:--
  1. Disconnect the batteries.
  2. Disconnect the EGR air transfer tube temperature sensor.
  3. Disconnect the EGR valve actuator connector.
  4. Disconnect the Engine Oil level tube at the Air Inlet bracket
  5. Loosen and remove both v-band clamps at each end of the air transfer tube
  6. Remove the P-clip mounting cap screw
  7. Remove the air transfer tube.
  8. Loosen and remove six air inlet mounting cap screws.
  9. Remove the air inlet.
  10. Remove the injector fuel lines.
  11. Disconnect the fuel rail pressure sensor at the rear of the fuel rail manifold.
  12. Remove the high pressure fuel line from the dump/overflow valve.
  13. Remove the fuel rail.
  14. Remove the grid heater wiring connector.
  15. Disconnect the TMAP sensor.
  16. Remove the intake manifold cap screws.
  17. Remove the intake manifold.
To install:
  1. Clean the intake manifold and cylinder head gasket area.
  2. Install a new intake manifold gasket.
  3. Position the intake manifold and Install the intake manifold cap screws finger tight.
  4. Position the fuel rail and install the fuel rail manifold cap screws finger tight.
  5. Tighten the intake manifold cap screws to 18 ft. lbs. (24 Nm).
  6. Connect the fuel rail pressure sensor.
  7. Connect the intake manifold grid heater. Torque the cap screw to 89 in. lbs. (10 Nm).
  8. Install the fuel lines.
  9. Tighten the fuel rail mounting cap screws to 18 ft. lbs. (24 Nm).
  10. Clean the air inlet gasket area.
  11. Clean the intake manifold to air inlet area.
  12. Install the new air intake connection gasket.
  13. Install the air intake connection to the intake manifold.
  14. Tighten the intake manifold to 18 ft. lbs. (24 Nm).
  15. Install the oil level gauge tube and torque to 18 ft. lbs. (24 Nm).
  16. Clean the gasket area of the air transfer Tube (both ends).
  17. Clean the EGR cooler and EGR control valve gasket area.
  18. Using new gaskets, install the air transfer tube.
  19. Install the V-band clamps.
  20. Install the P-clip to the bracket. Torque the mounting cap screw to 18 ft. lbs. (24 Nm).
  21. Tighten the V-band clamps to 89 lbs. in. (10 Nm).
  22. Connect the EGR valve actuator connector.
  23. Connect the EGR gas temperature connector.
  24. Connect the batteries.
  25. Start the engine and check for leaks.

These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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