removal of air intake manifold

[6.5 MONEY PIT]

hi everyone

I am not a mechanic but but do pretty much of my own work on my truck when possible , I just bought an new heat sink with out the pmd so I have to get my fsd or pmd off the side of the ij pump and the only way I seen doing that is remove the intake manifold . my question is , is there anything tricky about removing it or and short cuts or secrets to make this go as smooth as possible any help is appreciated thanks Dan :)

[6.5 on da bayou]

Well Dan,
Ive removed the intake on my dually at least 5 times now. 1st time about 4 hrs. to remove, now a little less than 2 hrs. Belt has to come off , then altenator (b/c of the bracket), then the turbo stabilizer bar, the fuel filter housing, the upper tube must be split from the turbo feed,and even some ground cables (front and rear). Then you can remove the 16 bolts that hold it down and remove the intake. There really is no short cut.

BUT,
Here is the catch,

Iv'e experienced it myself and have been told by others too, It is nearly IMPOSSIBLE to get to the lower screws that hold the pmd down without removing either (A) the right bank head, or (B) the whole injection pump. Both a severe pain in the butt

If you are not a patient mechanic, or if you dont have many hours to devote to this task, I would stongly recommend leaving your PMD where its at for a future (spare), Get a new module, and in five minutes your done. (Instead of tens of hours)

Good Luck,
Floyd

[99C2500]

Hi guys, the two bottom screws are removed with a #10 or 15 short torx bit ( I can't remember) and a 1/4 inch wrench and a lot of patience. cover your intake ports with clean rag and stuff a rag under the pmd then hold the bit in place with your finger and with your other hand turn the bit with your wrench. there may be an easier way but this method worked for me

Good luck

[6.5 MONEY PIT]

thanks guys I ll be devoting a saturday once the weather breaks.

[midniteplowboyy]

Get you a 1/4" ratchet wrench, like a gearwrench, if there is enough room to turn the torx bit. If there not tamper-proof torx bolts, you can grind both ends of your torx bit down to make it shorter, sorry if this advice does not apply here I have never changed a PMD but have used these tactics for other things.

Good Luck,