ISM, ISMe, and QSM11 – 010-080   Air Intake Connection

NOTE: Brush away any loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

• Disconnect the charge-air cooler connection. Cover open points with caps from the Air Handling Clean Care Kit.
• Disconnect the intake manifold air temperature sensor connector from the engine harness.
• Remove the air compressor inlet tube from the EGR mixer. Refer to Procedure 012-109 in Section 12.
• Remove the EGR connection tube from the EGR mixer. Refer to Procedure 011-025 in Section 11.
• Remove the EGR mixer. Refer to Procedure 011-021 in Section 11.

Remove the four capscrews holding the air intake connection to the intake manifold.

Remove and discard the gasket.

Cover open points with caps from the Air Handling Clean Care Kit or heavy tape.

Clean the air intake connection flange. After cleaning, cover the open points with caps from the Air Handling Clean Care Kit or heavy tape.

Clean the air intake connection mounting capscrews.

Inspect the air intake connection for cracks or other damage. Replace the connection if it is damaged.

Inspect the air intake connection capscrews for stripped threads or other damage. Replace the capscrews if they are damaged.

Install a new gasket between the intake manifold and the air intake connection.

Install the four capscrews finger tight.

Tighten the capscrews according in the sequence shown.

• Install the EGR mixer. Refer to Procedure 011-025 in Section 11.
• Install the EGR connection tube to the EGR mixer. Refer to Procedure 011-025 in Section 11.
• Connect the air compressor inlet tube to the EGR mixer. Refer to Procedure 012-109 in Section 12.
• Connect the intake manifold air temperature sensor connector to the engine harness.
• Connect the charge-air cooler connection. Refer to Procedure 010-027 in Section 10.

Operate the engine to normal operating temperature and check for air and exhaust leaks.

If damage resulted in coolant, oil, excessive fuel, or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 in Section 14.