Operation CHARM: Car repair manuals for everyone.

Intake Air Heater: Service and Repair



Intake Air Heater Replacement

Removal Procedure





1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (Service and Repair) .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
3. Remove the exhaust gas recirculation (EGR) valve motor. Refer to Exhaust Gas Recirculation Valve Motor Replacement (Service and Repair) .
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.
Caution: Refer to Fastener Caution (Fastener Caution) .
4. Install the IAH bolts (1) and nuts (2).

Tighten the bolts/nuts to 20 Nm (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 Nm (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 Nm (35 lb in).





13. Install the upper intake manifold brace and bolts.

Tighten the bolts to 24 Nm (18 lb ft).

14. Install the EGR valve motor. Refer to Exhaust Gas Recirculation Valve Motor Replacement (Service and Repair) .
15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (Service and Repair) .