Important: When servicing the upper intake manifold, always replace the upper intake gasket fold gasket for the L 56, always replace the sealing gasket between the upper and lower intake manifolds. Failure to replace this sealing gasket will cause a driveability problem.
The L 56 and L 65 upper intake manifold gaskets are not interchangeable.
1. Apply a small amount of silicone sealer to the turbocharger inlet and the upper intake manifold.
2. Install the air hose and clamps on the turbocharger.
3. Install the new upper intake (L 56) manifold gasket on the lower intake manifold.
4. Install the sealing gasket for the EGR valve on the lower intake manifold.
5. Install the upper intake (L 65) manifold gasket on the lower intake manifold.
Notice: Refer to Fastener Notice in Caution and Notices.
6. Install the mounting bolts in the upper intake manifold.
Tighten
Tighten the bolts to 23 N-m (17 Ib ft).
7. Insert upper intake manifold into the air intake hose the air intake hose.
Tighten
Tighten the clamps to 6 N-m (50 Ib in).
8. Install the EGR valve and gasket to the upper intake manifold (L 56 only). Refer to EGR Valve Replacement in Engine Controls-6.5L.
9. Install the boost pressure sensor on the upper intake manifold. Refer to Boost Sensor Replacement in Engine Controls 6.5L.
10. Install the intake air temperature sensor to the upper intake manifold. Refer to IAT Sensor Replacement in Engine Controls 6.5L.
11. Install the brace (long for the L 65 and short for the L 56) from the turbocharger to the upper intake manifold. Refer to Turbocharger Replacement
12. Install the upper engine cover to the upper intake manifold.
13. Connect both the battery negative cables to the batteries. Refer to Battery Cable in Engine Electrical.
