Dodge ram truck 3500 1996 Service Manual page 1217

BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15
REMOVAL AND INSTALLATION (Continued)
INTAKE MANIFOLD COVER—AIR INTAKE HEATER
REMOVAL
(1) Remove the charge air cooler (intercooler) out­
let duct from the air inlet housing (Fig. 33).
CLAMP
VALVE COVER
INTERCOOLER
INLET DUCT
CLAMP-
CLAMP
INTERCOOLER
OUTLET DUCT
CLAMP
J9509-53
Fig. 33 Intercooler Outlet Duct
(2) Remove air inlet housing.
(3) Remove the high pressure fuel lines.
(4) Disconnect the air intake heater power supply
lines (Fig. 34).
(5) Disconnect the charge air temperature sensor
from the intake manifold cover.
(6) Disconnect the air temperature switch from the
intake manifold cover.
(7) Remove the manifold intake cover and gasket
(Fig. 35). Keep the gasket material and any other
material out of the air intake.
(8) Clean the sealing surface.
INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Connect the air temperature switch to the
intake manifold cover.
(3) Connect the charge air temperature sensor to
the intake manifold cover.
(4) 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 N-m (18 ft. lbs.)
torque.
(5) Install a new gasket on top of the air intake
heater.
GASKET
AIR INTAKE
HEATER POWER
SUPPLY LINES
INTAKE
MANIFOLD
COVER
MANIFOLD
COVER
BOLTS
AIR INTAKE
- HEATER
ELEMENTS
CABLE
i ^MOUNTING
- ^ ^ ^ STUDS (2)
7
FORWARD«
INTAKE
MANIFOLD
8 0 5 d d 8 f
Fig. 34 Air Intake Heater
INTAKE MANIFOLD AIR HEATER
Fig. 35 Manifold Intake Cover
(6) Install the air inlet housing. Tighten the air
inlet housing bolts to 24 N-m (18 ft. lbs.) torque.
(7) Install and tighten the air intake heater power
supply nuts to 14 N-m (10 ft. lbs.) torque.
(8) Position the charge air cooler (intercooler) out­
let duct onto the air inlet housing. Tighten the