INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

Note:

  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

    Click hereClick hereClick hereClick hereClick here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click hereClick hereClick hereClick hereClick hereClick here

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  4. DISCONNECT ENGINE WIRE

    Click here

  5. REMOVE EGR VALVE BRACKET

    Click here

  6. REMOVE NO. 7 WATER BY-PASS HOSE

    1. A197539

      Slide the clamp and remove the No. 7 water by-pass hose from the electric EGR control valve assembly.

  7. DISCONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  8. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  9. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  11. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Click here

  12. REMOVE COMMON RAIL ASSEMBLY

    Click here

  13. REMOVE INTAKE MANIFOLD INSULATOR

    1. A197550

      Remove the intake manifold insulator from the intake manifold.

  14. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Remove the engine oil level dipstick.

    2. A291312

      Disconnect the connector and detach the wire harness clamp from the engine oil level dipstick guide.

    3. Remove the 2 bolts and engine oil level dipstick guide.

    4. Remove the O-ring from the engine oil level dipstick guide.

  15. REMOVE DIESEL TURBO PRESSURE SENSOR

    Click here

  16. REMOVE NO. 1 GAS FILTER

    1. A206311

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  17. REMOVE GAS FILTER BRACKET

    1. A206312

      Remove the 2 bolts and gas filter bracket.

  18. REMOVE ENGINE COVER BRACKET

    1. A197556

      Remove the bolt and engine cover bracket.

  19. REMOVE NO. 2 INTAKE MANIFOLD

    1. A197557

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  20. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A201877

      Slide the clamp and disconnect the No. 2 vacuum transmitting hose assembly from the intake manifold.

  21. REMOVE INTAKE MANIFOLD

    1. A197558C02

      *1

      Nut

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

  22. REMOVE STUD BOLT

    Tip:

    If a stud bolt is deformed or the threads are damaged, replace it.