INTAKE MANIFOLD (w/ EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE MANIFOLD STAY


    1. Disconnect the 3 vacuum hoses from the 2 VSV.

    2. A01E1Y6

      Remove the 2 bolts and stay.

  3. REMOVE OIL DIPSTICK GUIDE

    A01DZT2

    1. Remove the bolt and injection pipe clamp.

    2. Remove the bolt and guide.

    3. Remove the O-ring from the guide.

  4. REMOVE EGR COOLER


    1. Remove the EGR cooler Click here.

  5. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. A01DWTK

      Remove the bolt and support bracket.

  6. REMOVE VACUUM CONTROL VALVE SET


    1. A01E2B6

      Disconnect the 2 connectors and 3 vacuum hoses.

    2. Remove the 2 bolts and vacuum control valve set.

  7. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

    2. A01DVY2E02

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  8. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DVSC

      Remove the check valve, 3 bolts, leakage pipe and gasket.

  9. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01DZGR

      Remove the 2 bolts and insulator from the manifold.

  10. REMOVE INTAKE MANIFOLD


    1. A01DZ43

      Disconnect the common rail sub-harness connector from the intake manifold.

    2. A01E1P8

      Remove the 2 nuts, 4 bolts, intake manifold and gasket.