Intake Air Heater: Service and Repair

Intake Air Heater Replacement

Removal Procedure




1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Remove the exhaust gas recirculation (EGR) valve motor.
4. Remove the upper intake manifold brace bolts and brace.




5. Remove the engine wiring harness clip (1) from the intake manifold tube.
6. Remove the engine wiring harness clip bolt (2) from the intake manifold tube.




7. Disconnect the engine wiring harness electrical connector (1) from the intake air heater (IAH).
8. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
9. Reposition the engine wiring harness branches out of the way.




10. Open the IAH harness lead cover (2).
11. Remove the engine wiring harness lead nut (1) from the IAH stud.
12. Remove the engine wiring harness lead (3) from the IAH stud.




13. Remove the IAH bolts (1) and nuts (2).
14. Remove the intake manifold front tube and IAH from the intake manifold rear tube.
15. Remove the IAH (3) from the intake manifold front tube studs.
16. Remove and discard the IAH gasket.

Installation Procedure




1. Install a NEW IAH gasket.
2. Install the IAH (3) to the intake manifold front tube studs.
3. Install the intake manifold front tube and IAH to the intake manifold rear tube.

Notice: Refer to Fastener Notice.

4. Install the IAH bolts (1) and nuts (2).

Tighten the bolts/nuts to 20 N.m (15 lb ft).




5. Install the engine wiring harness lead (3) to the IAH stud.
6. Install the engine wiring harness lead nut (1) to the IAH stud.

Tighten the nut to 10 N.m (89 lb in).

7. Close the IAH harness lead cover (2).




8. Position the engine wiring harness branches.
9. Connect the engine wiring harness electrical connector (2) to the MAP sensor.
10. Connect the engine wiring harness electrical connector (1) to the IAH.




11. Install the engine wiring harness clip (1) to the intake manifold tube.
12. Install the engine wiring harness clip bolt (2) to the intake manifold tube.

Tighten the bolt to 4 N.m (35 lb in).




13. Install the upper intake manifold brace and bolts.

Tighten the bolts to 24 N.m (18 lb ft).

14. Install the EGR valve motor.
15. Install the air cleaner assembly.
16. Connect the negative battery cable.