ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 1 of 41 FUEL SYSTEMS ACCELERATOR PEDAL POSITION SENSOR Removal & Installation Disconnect the APP sensor harness connector. See Fig. 4. Remove the accelerator pedal mounting nuts. Remove the APP assembly. To install, reverse removal procedure. Verify that the vehicle meets the following conditions: The vehicle is not in a Reduced Engine Power mode. The ignition is ON. The engine is OFF. Operate the accelerator pedal and observe the APP angles with a scan tool. The accelerator pedal should operate freely, without binding, between closed throttle and Wide Open Throttle (WOT). Inspect the carpet fit under the accelerator pedal.
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 2 of 41 Fig. 4: Locating APP Sensor BARO SENSOR Removal & Installation Turn OFF the ignition. Disconnect the BARO sensor electrical connector. See Fig. 5. Bend the locking tab, located on the bracket, away from the sensor, just enough so that the sensor will pass.
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 3 of 41 Pull the BARO sensor downward to remove it from the bracket. To install, reverse removal procedure. Fig. 5: Locating BARO Sensor BOOST SENSOR Removal & Installation (Calif.) 1. Turn OFF the ignition. Loosen the outlet duct clamp at the upper intake manifold cover. Remove he upper intake manifold cover from the outlet duct. Remove the upper intake manifold cover. Disconnect the electrical connector from the boost pressure sensor. See Fig. 6. Remove the bolt retaining the boost pressure sensor bracket. Disconnect the vacuum line from
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 4 of 41 2. the sensor. Remove the boost pressure sensor and the bracket. Remove the bracket from the sensor. To install, reverse removal procedure. Inspect the boost pressure sensor seal for damage and replace as necessary. Fig. 6: Locating Boost Sensor (Calif.) Removal & Installation (Federal) 1. 2. Turn OFF the ignition. Remove the air cleaner outlet duct. Disconnect the electrical connector from the boost pressure sensor. See Fig. 7. Remove the nut retaining the boost pressure sensor bracket and the coolant tube. Lift the coolant tube off of the stud and move it out of the way. Remove the boost pressure sensor and the bracket from the intake manifold. Remove the bracket from the sensor. To install, reverse removal procedure. Inspect the boost pressure sensor seal for damage and replace as necessary.
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 5 of 41 Fig. 7: Locating Boost Sensor (Federal) CAMSHAFT POSITION SENSOR Removal & Installation
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 6 of 41 Remove the cooling fan. Disconnect the camshaft position sensor connector. See Fig. 8. Remove the cooling fan pulley. Remove the CMP sensor retaining bolt. Remove the CMP sensor. To install, reverse removal procedure. Fig. 8: Locating CMP Sensor (6.6L) CRANKSHAFT POSITION SENSOR NOTE: Some models require CRANKSHAFT POSITION (CKP) SENSOR VARIATION LEARN PROCEDURE to be performed when CKP sensor is
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 7 of 41 removed or replaced. See COMPUTER RELEARN PROCEDURES - DOMESTIC article in GENERAL INFORMATION. Removal & Installation Disconnect the batteries. Remove the CKP sensor connector. Remove the CKP sensor mounting bolt. Remove the CKP sensor. See Fig. 9. To install, reverse removal procedure. Fig. 9: Locating CKP Sensor (6.6L)
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 8 of 41 ECT SENSOR Removal & Installation Turn OFF the engine. Drain the coolant below the level of the ECT sensor. Disconnect the ECT sensor electrical connect. See Fig. 10. Remove the ECT sensor. To install, reverse removal procedure. Fig. 10: Locating ECT Sensor EGR VALVE Removal & Installation
ENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATION - 6.6L DIESEL... Page 9 of 41 1. 2. 3. Drain cooling system. Remove air intake duct. See Fig. 6. Remove the turbocharger boost sensor bracket bolt. Remove the turbocharger boost sensor with bracket. Remove the intake heater and gasket. Remove the upper intake manifold tube nuts and upper tube. Disconnect Exhaust Gas Recirculation (EGR) valve vacuum hose. Remove EGR inlet cooling hose from cooling tube. Remove EGR outlet cooling hose from cooling tube. Remove nuts retaining EGR assembly to intake manifold. Remove nuts retaining EGR assembly to exhaust pipe. Remove bolts retaining EGR assembly to EGR bracket. Remove EGR assembly from engine. Remove bolts retaining EGR to EGR cooling tube. Separate EGR from EGR cooling tube. To install, reverse removal procedure. EGR VALVE THROTTLE SOLENOID Removal & Installation Disconnect the negative battery cable. Remove the right turbo charged air hose. Disconnect the Exhaust Gas Recirculation (EGR) throttle valve solenoid electrical connector. See Fig. 11. Disconnect the EGR throttle valve solenoid vacuum lines. Remove the solenoid bolt and the solenoid. To install, reverse removal procedure.
Page 10 of 41 Fig. 11: Locating EGR Valve Throttle Solenoid EGR VALVE VACUUM PUMP Removal & Installation Remove the lower fan shroud. Remove vacuum line from Exhaust Gas Recirculation (EGR) valve vacuum pump. Remove the drive belt tensioner. Remove the drive belt idler pulley. Remove EGR vacuum pump mounting nuts. Remove the EGR vacuum pump. To install, reverse removal procedure. EGR VALVE VACUUM SENSOR Removal & Installation
Page 11 of 41 Disconnect the negative battery cable. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum sensor electrical connector. See Fig. 12. Disconnect the EGR valve vacuum sensor vacuum line. Remove the EGR valve vacuum sensor from the bracket. To install, reverse removal procedure. Fig. 12: Locating EGR Valve Vacuum Sensor EGR VALVE VENT SOLENOID Removal & Installation Disconnect the negative battery cable. Disconnect the Exhaust Gas Recirculation (EGR) valve vent solenoid electrical connector. See Fig. 13. Disconnect the EGR vent solenoid vacuum lines. Remove the EGR valve vent solenoid bolt and the solenoid. To install, reverse removal procedure.
Page 12 of 41 Fig. 13: Locating EGR Vent Valve Solenoid EGR VALVE SOLENOID Removal & Installation Disconnect the negative battery cable. Disconnect the Exhaust Gas Recirculation (EGR) valve solenoid. See Fig. 14. Disconnect the EGR valve solenoid vacuum lines. Remove the EGR valve solenoid bolt and the solenoid. To install, reverse removal procedure.
Page 13 of 41 Fig. 14: Locating EGR Valve Solenoid FUEL FILTER Removal Tips Click a link to view tip Tip: Duramax Diesel Fuel Filter Replacement Problems Tip: FUEL FILTER LIFE indicator reset Disconnect the negative battery cables. Install a hose to the water drain on the water-in-fuel sensor. See Fig. 15. Place the other end of the hose into an approved container. Drain as much fuel as
Page 14 of 41 possible from the fuel filter housing. Tighten the water drain on the water-in-fuel sensor. Disconnect the water-in-fuel sensor harness connector. Remove the fuel filter from the fuel filter/heater element housing. Remove the water-in-fuel sensor from the fuel filter. Installation Tips Click a link to view tip Tip: WIF Sensor Installation Tip: FUEL FILTER LIFE indicator reset NOTE: Inspect the fuel filter/heater element housing and the fuel filter for a dislocated filter seal or contamination. Contamination on the fuel filter/heater element housing may cause leakage at the fuel filter. Coat the seal with clean engine oil. Install the water-in-fuel sensor in the fuel filter. Install the fuel filter on the fuel filter/heater element housing. Connect the water-in-fuel harness connector. Pump Primer located on top of the fuel filter 30 times or until stiff. Connect the negative battery cables. Start the engine and inspect for fuel leaks.
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Page 17 of 41 Fig. 15: Identifying Fuel Filter Components (6.6L) FUEL INJECTION CONTROL MODULE Removal & Installation 1. 2. 3. 4. Disconnect the batteries. Remove the duct between the air cleaner and the turbocharger inlet housing. Remove the clamp from the PCV hose to pipe and move the hose aside. Remove the fuel filler cap to relieve pressure. Remove the large tie wraps from the fuel injector control module and harness. Loosen the fuel lines at the fuel injection control module. Remove the 3 mounting bolts. Remove the insulators between the fuel injection control module and bracket by lifting up the module and reaching underneath. Disconnect the wiring harness connectors from the fuel injection control module. Disconnect the fuel lines at the fuel injection control module and discard washers. Remove the fuel injection control module from the bracket. See Fig. 16. Use NEW washers on fuel lines. Do not knock off the insulators when installing the fuel injector control module to the bracket. To install, reverse removal procedure.
Page 18 of 41 Fig. 16: Locating FICM FUEL INJECTION PUMP Removal & Installation NOTE: Cover the air intake pipe end with duct tape to prevent the infiltration of dirt.
Page 19 of 41 1. Disconnect negative battery cables from both batteries. Remove the air intake duct between the air cleaner and the turbocharger inlet housing. Drain the coolant. Remove the upper fan shroud. Remove the fan blade assembly. Remove the serpentine belt. Remove the bolt holding the positive battery cable junction box and bracket and move out of the way. NOTE: Remove only the air conditioning/power steering bracket. Do not discharge the A/C or remove the A/C and power steering lines. 2. 3. Remove the A/C compressor. See appropriate article in AIR CONDITIONING & HEATING. Remove the power steering pump. Position the A/C compressor and power steering pump aside. Remove the oil filler tube. Remove the air conditioning/power steering bracket. Remove the alternator. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts. Remove the Positive Crankcase Ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and reposition. Remove the alternator bracket. Remove the turbo cooling hose return line clamp and hose. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way. Remove bolt holding wiring support bracket at thermostat housing. Move the main wiring harness by disconnecting the fuel pressure regulator connector on the fuel injection pump and the fuel injection control module connectors. Flip the wire harness and harness tray towards the back and set aside. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing. NOTE: Cap all of the open fuel connections with suitable plastic plugs in order to prevent infiltration of dirt. 4. 5. 6. Remove the air intake pipe. Remove the thermostat crossover assembly. Remove the hose to the turbo water feed line. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and function block. Remove the high pressure line from the injection pump to the junction block. Remove the fuel return hose from fuel injection pump. Remove the high pressure line from the injection pump to the junction block. Remove fuel injection pump from the block using two screwdrivers to work the pump from the block towards rear of engine keeping the pump straight. Remove fuel injection pump. See Fig. 17. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Page 20 of 41 Fig. 17: Removing Fuel Injection Pump (6.6L) FUEL INJECTOR Tips Click a link to view tip Tip: Injector Sleeve
Page 21 of 41 Removal Remove the lower valve rocker arm cover. Remove the return line from injectors. Remove the retaining bolt from the injector bracket. Install the Fuel Injector Puller (J 44639) on the injector retainer bracket. Confirm which side of the banjo washers have the largest hole. Install a wrench on the J 44639 and pry away from the fuel injector. Remove the faulty injectors. See Fig. 18. Remove the copper compression washer from injection hole if the washer did not remove with the injector. Installation NOTE: Always install new copper gaskets on the fuel injector lines. 1. 2. 3. If the injector sleeve was pulled from the cylinder head when removing the injector(s), continue with this step. If the injector sleeve was not pulled from cylinder head, go to step 3. Clean the fuel injector sleeve bore with GM P/N 12377981 or equivalent. Lubricate and install NEW "O" rings onto the fuel injector sleeve. Install the fuel injector sleeve onto the Fuel Injector Sleeve Remover/Installer (J 45910). Apply GM P/N United States 12345493 or equivalent to the fuel injector sleeve lower sealing area. Install the fuel injector sleeve with J 45910 into the cylinder head. Lightly tap on the J 45910 with a hammer to install and seat the fuel injector sleeve. Remove the J 45910 from the fuel injector sleeve. Install the NEW injectors. Install the retaining bolt on the injector bracket. Install the return line fuel injector. Install the lower left valve rocker arm cover.
Page 22 of 41 Fig. 18: Removing Fuel Injector FUEL PRESSURE REGULATOR Removal & Installation 1. Remove the air intake pipe. Disconnect the Air Conditioning (A/C) compressor clutch electrical connector. Disconnect the A/C cut out switch electrical connector. Remove the drive belt. Remove the A/C compressor bolts. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
Page 23 of 41 2. 3. 4. 5. Remove the water outlet tube. Disconnect both main harness electrical connectors. Remove both main harness electrical connector to bracket bolts. Remove the main harnesses from the bracket. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. Disconnect the Barometric (BARO) pressure sensor electrical connector. Disconnect the glow plug relay electrical connectors. Disconnect the fuel rail temperature sensor electrical connector. Disconnect the left front fuel injector electrical connector. Disconnect the left rear fuel injector electrical connector. Disconnect the fuel pressure regulator electrical connector. Disconnect the oil level sensor harness electrical connector. Remove the Positive Crankcase Ventilation (PCV) hose from both valve covers. Reposition the injection pump inlet clamp. Remove the injection pump inlet hose from the fuel feed distribution (leak-off) block. Reposition the hose. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981, or equivalent. Using compressed air, thoroughly blow dry the regulator and pump. Remove the 3 fuel pressure regulator screws using a T25 TORX(R). Remove the fuel pressure regulator. See Fig. 19. NOTE: DO NOT use compressed air to remove debris while the fuel pressure regulator is removed. 6. 7. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following: Place a clean rag over the pump bore in order to collect the excess fuel. Bump the engine over in order to flush any debris out of the regulator bore. If the pressure regulator is being re-used, check the "O" rings for damage. If the "O" rings are damaged, install NEW "O" rings. Lubricate and install NEW "O" rings onto the regulator. Lubricate the "O" rings with clean, NEW engine oil. If the regulator is installed at an angle the "O" rings may be damaged, resulting in possible fuel leakage. To install, reverse removal procedure.
Page 24 of 41 Fig. 19: Locating Fuel Pressure Regulator FUEL PUMP Tips Click a link to view tip Tech1 Question: Won't start, fuel pump??
Page 25 of 41 WARNING: Replace the "O" ring seals exposed during component service in order to reduce the risk of fire and personal injury that may result from a fuel leak. Removal & Installation 1. 2. Loosen filler caps to relieve the fuel system pressure. Raise the vehicle. Disconnect the fuel pump harness connector. See Fig. 20. Clean both fuel pipe connections and surrounding areas at the fuel pump before disconnecting to avoid possible contamination of the fuel system. Disconnect both fuel pipes from the pump. Slide the pump out of the bracket. Cap the fuel pipes. To install, remove the caps from the fuel pipes. Install the new fuel pipe "O" rings. To complete installation, reverse removal procedure.
Page 26 of 41 Fig. 20: Locating Fuel Pump FUEL RAIL ASSEMBLY Removal & Installation (Right Bank) 1. Remove negative battery cable. Drain cooling system. Remove upper radiator hose and clamps. Remove bolt holding positive battery cable junction block and move out of way. Remove the turbo charged air outlet hose. Remove glow plug relay connectors and remove bracket.
Page 27 of 41 2. 3. Disconnect 24-pin and 40-pin engine connectors. Remove the engine connector bracket and set aside. Remove fuel pressure line, return line and "L" bracket. Remove Positive Crankcase Ventilation (PCV) line and set aside. Remove water pipe outlet at thermostat housing. Remove serpentine belt. Remove A/C compressor and position aside without disconnecting lines. Remove line from junction block to injector pump. Loosen and remove high pressure line at back end of fuel rail. Remove junction block. Loosen lines at injectors first and then loosen lines at fuel rail. Mark high pressure lines before removing for reference during installation. Remove 3 fuel rail bolts and remove fuel rail from vehicle. See Fig. 21. To install, reverse removal procedure. Removal & Installation (Left Bank) 1. 2. 3. Disconnect the negative battery cables from both batteries. Drain the cooling system. Remove the air cleaner outlet duct. Remove the right side charged air outlet hose and clamps. Remove the Positive Crankcase Ventilation (PCV) hose and clamp. Remove the fuel injection control module. See FUEL INJECTION CONTROL MODULE. Remove the fuel filter. Remove the Exhaust Gas Recirculation (EGR) valve. See EGR VALVE. Disconnect the high pressure fuel rail line coming from the junction block. Loosen the high pressure injection lines at the four injectors. Loosen the high pressure lines injection at the four fittings on the fuel rail. Mark the high pressure injection lines in order and remove them. Remove the 3 bolts holding the fuel rail. See Fig. 21. To install, reverse removal procedure.
Page 28 of 41 Fig. 21: Locating Fuel Rail (Right Side Shown, Left Side Similar) FUEL RAIL PRESSURE SENSOR Removal Remove the Air Conditioning (A/C) compressor. See FUEL PRESSURE REGULATOR. Disconnect the fuel rail pressure sensor electrical connector. Remove the sensor and metal gasket from the junction block. Discard the gasket. See Fig. 22.
Page 29 of 41 Installation Install the sensor and a NEW metal gasket to the junction block. If a crows foot is used to torque the sensor then special attention to the position of the crows foot in relation to the torque wrench is required. If the crows foot is kept perpendicular (90 degrees) to the torque wrench during the entire tightening procedure, then the torque wrench can be set to the listed torque specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure Fig. 22: Locating Fuel Rail Pressure Sensor FUEL RAIL TEMPERATURE SENSOR Removal & Installation
Page 30 of 41 Loosen the outlet duct clamp at the upper intake manifold cover. Remove the upper intake manifold cover from the outlet duct. Remove the upper intake manifold cover. Remove the turbo charged air outlet duct over the left valve cover. Remove the fuel temperature sensor harness connector. Remove the fuel temperature sensor from the fuel rail. See Fig. 23. To install, reverse removal procedure. Fig. 23: Locating Fuel Rail Temperature Sensor FUEL RETURN HOSE Removal & Installation 1. Disconnect the negative battery cable. Drain the cooling system. Remove the air cleaner outlet duct. Remove the right turbo charged air outlet hose. Remove the left turbo charged air outlet hose. Remove the engine wiring harness.
Page 31 of 41 2. Remove the water outlet pipe. Remove the fuel hose from fuel return line. Remove the fuel hose from fuel injection pump and remove from engine. To install, reverse removal procedure. FUEL SYSTEM COOLER Removal & Installation (Cab & Chassis) Raise the vehicle. Disconnect the fuel pipes from the fuel cooler. See QUICK CONNECT FITTINGS (METAL COLLAR). Remove the retaining nuts from the chassis crossmember. Remove the fuel cooler. See Fig. 24. To install, reverse removal procedure. Fig. 24: Locating Fuel System Cooler (Cab & Chassis) Removal & Installation (Pickup)
Page 32 of 41 Raise the vehicle. Relieve the fuel pressure. Disconnect the fuel pipes from the fuel cooler. See QUICK CONNECT FITTINGS (METAL COLLAR). Remove the retaining bolts from the chassis and crossover. Remove the fuel cooler. Remove the fuel cooler support bracket from the fuel cooler. See Fig. 25. To install, reverse removal procedure.
Page 33 of 41 Fig. 25: Locating Fuel System Cooler (Pickup) FUEL TANK Removal & Installation (Cab & Chassis Auxiliary) 1. 2. 3. Drain the fuel tank. Raise the vehicle. Remove the fuel tank shield. Disconnect the fuel fill and vent pipes from the fuel tank. Support the fuel tank, with the aid of an assistant. Remove the fuel tank strap attaching bolts. Remove the fuel tank straps. Lower the fuel tank slightly. Disconnect the fuel pipes from the fuel sender. See QUICK CONNECT FITTINGS (METAL COLLAR). Disconnect the fuel sender harness connector. Remove the fuel tank. Place the fuel tank in a suitable work area. Cap the fuel pipes in order to prevent possible fuel system contamination. To install, reverse removal procedure. Removal & Installation (Cab & Chassis Primary) 1. 2. 3. Drain the fuel tank. Raise the vehicle. Remove the fuel tank shield. Disconnect the fuel fill and vent pipes from the fuel tank. Support the fuel tank, with the aid of an assistant. Remove the fuel tank strap attaching bolts. Remove the fuel tank straps. Lower the fuel tank slightly. Disconnect the fuel pipes from the fuel sender. See QUICK CONNECT FITTINGS (METAL COLLAR). If equipped with an auxiliary fuel tank disconnect the rear chassis balance pipes. Disconnect the fuel sender harness connector. Remove the fuel tank. Place the fuel tank in a suitable work area. Cap the fuel pipes on the vehicle in order to prevent possible fuel system contamination. To install, reverse removal procedure. Removal & Installation (Pickup) 1. 2. 3. Drain the fuel tank. Raise the vehicle. Disconnect the fuel fill hose from the fuel tank. Remove the fuel system cooler. See FUEL SYSTEM COOLER. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. See QUICK CONNECT FITTINGS (METAL COLLAR). Cap the fuel pipes in order to prevent possible fuel system contamination. Disconnect the fuel sender electrical connector. Remove the fuel tank shield. With the aid of an assistant, support the fuel tank. Remove the fuel tank strap attaching bolts. Remove the fuel tank straps. Remove the fuel tank. Place the fuel tank in a suitable work area. Remove the fuel feed pipe and the fuel return pipe from the fuel sender and the retaining clips. To install, reverse removal procedure. GLOW PLUG Removal & Installation NOTE: On the Federal Emissions systems there is a buss bar connecting the glow plugs on each bank of the engine.
Page 34 of 41 Disconnect the batteries. Remove the appropriate front wheel well. Remove the air cleaner outlet duct. Remove the electrical nuts from the desired glow plugs. Remove the harness from the desired glow plugs. Remove the desired glow plugs. To install, reverse removal procedure. Tighten glow plug to specification. See TORQUE SPECIFICATIONS. GLOW PLUG RELAY Removal & Installation (Calif.) 1. 2. Disconnect the negative battery cables. Loosen the outlet duct clamp at the upper intake manifold cover. Remove he upper intake manifold cover from the outlet duct. Remove the upper intake manifold cover. Remove the battery supply wiring harness nut and harness connector from the glow plug controller battery voltage supply post. Remove the glow plug wiring harness connectors from the glow plug controller. Remove the glow plug controller mounting bolt from the mounting bracket. Remove the glow plug controller from the mounting bracket. See Fig. 26. To install, reverse removal procedure.
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Page 37 of 41 Fig. 26: Locating Glow Plug Relay (Calif.) Removal & Installation (Federal) 1. 2. Disconnect the negative battery cables. Loosen the outlet duct clamp at the upper intake manifold cover. Remove he upper intake manifold cover from the outlet duct. Remove the upper intake manifold cover. Remove the battery supply wiring harness nut and harness connector. Remove the glow plug wiring harness nuts and harness connectors. See Fig. 27. Release the wiring harness connectors at the glow plug relay. Remove the two glow plug relay mounting nuts. Remove the glow plug relay from the mounting studs. To install, reverse removal procedure.
Page 38 of 41 Fig. 27: Locating Glow Plug Relay (Federal) INTAKE AIR HEATER Removal & Installation
Page 39 of 41 Loosen the outlet duct clamp at the upper intake manifold cover. Remove he upper intake manifold cover from the outlet duct. Remove the upper intake manifold cover. Remove the intake air heater harness connector nut. Remove the intake air heater from the inlet pipe. See Fig. 28. To install, reverse removal procedure.
Page 40 of 41 Fig. 28: Locating Intake Air Heater MAF/IAT SENSOR Removal & Installation Disconnect the electrical connector of the Mass Air Flow/Intake Air Temperature (MAF/IAT) sensor. See Fig. 29. Remove the mounting bolts of the MAF/IAT sensor from the upper housing of the air cleaner assembly. Remove the MAF/IAT sensor. To install, reverse removal procedure. Fig. 29: Locating MAF/IAT Sensor
Page 41 of 41 PURGING FUEL SYSTEM Pump primer located on top of fuel filter 30 times or until stiff. Start engine and let idle. Check for leaks. QUICK CONNECT FITTINGS (METAL COLLAR) Removal Disconnect the negative battery cable. Remove the fuel filler cap. Remove the retainer from the quick -connect fitting. Blow dirt out of the fitting using compressed air. Choose the correct end of the fuel line disconnect tool for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs. Pull the connection apart. Use a clean shop towel in order to wipe off the male pipe end. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Installation Apply a few drops of clean engine oil to the male pipe end. Push both sides of the fitting together in order to snap the retaining tabs into place. Once installed, pull on both sides of the fitting to ensure the connection is secure. Install the retainer to the quick-connect fitting. Install the fuel filler cap. Connect the negative battery cable. QUICK CONNECT FITTINGS (PLASTIC COLLAR) Removal Disconnect the negative battery cable. Remove fuel filler cap. Using compressed air, blow any dirt out of the quick-connect fitting. Squeeze the plastic retainer release tabs. Pull the connection apart. Installation Apply a few drops of clean engine oil to the male fuel pipe end. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. Once installed, pull on both sides of the quick-connect fitting to ensure the connection is secure. Install the fuel filler cap. Connect the negative battery cable. 2008 Mitchell Repair Information Co., LLC.