3500 4x2 Pickup L6-359 5.9L DSL Turbo (1994)
Charge Air Temperature Sensor And Air Temperature Switch
5. Disconnect the charge air temperature sensor from the intake manifold cover.
6. Disconnect the air temperature switch from the intake manifold cover.
Manifold Intake Cover And Fuel Heater Ground Wire
7. Disconnect the fuel heater ground wire from the intake manifold cover.
8. Remove the manifold intake cover and gasket. Keep the gasket material and any other material out of the air intake.
9. Clean the sealing surface.
INSTALLATION
1. Using a new gasket, install the intake manifold cover.
2. Install the fuel heater ground wire. Tighten the bolt to 12 Nm (110 in.lbs.) torque.
3. Connect the air temperature switch to the intake manifold cover.
4. Connect the charge air temperature sensor to the intake manifold cover.
5. Some of the intake manifold bolt holes are drilled through and must be sealed. Apply liquid teflon sealant to the bolts. Install the intake manifold
cover bolts. Tighten the bolts to 24 Nm (18 ft lb) torque.
6. Install a new gasket between the air intake heater and the intake manifold cover. Install a new gasket on top of the air intake heater.
7. Install the air inlet tube. Tighten the air inlet tube bolts to 24 Nm (18 ft.lbs.) torque.
8. Connect the intake manifold heater ground wire.
9. Install and tighten the air intake heater power supply nuts to 14 Nm (10 ft.lbs.) torque.
10. Position the charge air cooler (intercooler) outlet duct onto the air inlet tube. Tighten the charge air cooler (intercooler) outlet duct clamps to 8
Nm (74 in.lbs.) torque.
11. Install and bleed the high pressure fuel lines. Tighten the high pressure fuel line nuts to 24 Nm (18 ft.lbs.) torque.
