INTAKE MANIFOLD INSTALLATION

CAUTION / NOTICE / HINT

Note

When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

Replaced Parts (A)	Pipes Requiring New Replacement
Injector assembly (including shuffling the injector assemblies between the cylinders) Common rail assembly Cylinder head sub-assembly	No. 1 injection pipe sub-assembly No. 2 injection pipe sub-assembly No. 3 injection pipe sub-assembly No. 4 injection pipe sub-assembly
Supply pump assembly Common rail assembly Cylinder block sub-assembly Cylinder head sub-assembly Cylinder head gasket Timing Gear Case Assembly	Fuel inlet pipe sub-assembly

After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE

INSTALL INTAKE MANIFOLD
1. Install a new gasket to the cylinder head sub-assembly.
2. Temporarily install the intake manifold with the 4 bolts 2 nuts.
3. Tighten the 4 bolts 2 nuts and in the order shown in the illustration.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
4. Connect the vacuum hose and connector to the vacuum switching valve.
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

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INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

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INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

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INSTALL INTAKE AIR CONNECTOR
1. Install a new gasket and the intake air connector to the intake manifold with the 2 nuts and bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET
1. Install the No. 2 intake air connector bracket to the cylinder head sub-assembly and intake manifold with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL VACUUM SWITCHING VALVE BRACKET
1. Install the vacuum switching valve bracket with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a small amount of clean engine oil to the O-ring.
2. Install a new O-ring to the engine oil level dipstick guide.
3. Install the engine oil level dipstick guide with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
4. Install the injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
5. Install the engine oil level dipstick.
INSTALL MANIFOLD STAY
1. Install the manifold stay to the intake manifold and cylinder block sub-assembly with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
  
  Tech Tips
  
  The manifold stay indented area (labeled A) must face the intake manifold.
INSTALL DIESEL THROTTLE BODY ASSEMBLY

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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

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BLEED AIR FROM FUEL SYSTEM

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INSPECT FOR FUEL LEAK

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