INTAKE MANIFOLD (w/o DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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 here.

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

  2. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Remove the electric EGR control valve assembly Click here.

  3. DISCONNECT INLET HEATER WATER HOSE (w/o EGR System)


    1. A01DSEF

      Remove the bolt and disconnect the inlet heater water hose.

  4. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)


    1. A01DOGA

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  5. REMOVE NO. 1 INTAKE PIPE (w/o EGR System)


    1. A01DN3I

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A01DNIV

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A01DQ50

      Loosen the hose clamp of the intercooler air hose.

    6. A01DMJ4

      Remove the 2 bolts and No. 1 intake pipe.

  6. REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A01DS9F

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  7. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating the injector inlet.


    1. A01DT2A

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A01DUQA

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. A01DO1DE01
      Text in Illustration
      *a for Injector Side
      *b for Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  8. REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A01DQZJ

      Remove the 3 bolts and air connector stay.

  9. DISCONNECT ENGINE WIRE (w/o EGR System)


    1. A01DOC8

      for LHD:

      Remove the 2 bolts and disconnect the clamp and engine wire.

    2. A01DOKK

      for RHD:

      Remove the bolt and disconnect the engine wire.

  10. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. A01DO8N

      Disconnect the throttle position sensor connector.

    2. A01DSBE

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A01DU30

        w/o EGR System:

        Disconnect the connector.

      2. A01DSOX

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A01DU9F

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A01DR0B

      Disconnect the No. 1 vacuum transmitting hose.

    3. A01DUDJ

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A01DNW0

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A01DSHRE03
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    6. A01DUH7

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  12. REMOVE INTAKE PIPE OR HOSE STAY


    1. A01DM2W

      Remove the bolt and intake pipe stay.

  13. REMOVE VACUUM CONTROL VALVE SET


    1. A01DPPT

      Disconnect the 2 VSV connectors and 3 vacuum hoses.

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

  14. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DO5J

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01DUTCE06
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

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

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DNQTE01
      Text in Illustration
      *1 Union Bolt

      Disconnect the 3 fuel hoses.

    2. Remove the union bolt, 4 bolts, No. 2 nozzle leakage pipe and gasket.

  16. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01DQZY

      Remove the 2 bolts and intake manifold insulator.

  17. REMOVE INTAKE MANIFOLD


    1. A01DNKHE01
      Text in Illustration
      *1 Sensor Wire

      Detach the sensor wire connector clamp from the intake manifold.

    2. A01DTMI

      Disconnect the vacuum hose from the intake manifold.

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