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. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  2. DISCONNECT ENGINE WIRE

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  3. REMOVE EGR VALVE BRACKET

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  4. REMOVE NO. 7 WATER BY-PASS HOSE

    A004O4V

  5. DISCONNECT NO. 8 WATER BY-PASS HOSE

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  6. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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  7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  9. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  10. REMOVE COMMON RAIL ASSEMBLY

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  11. REMOVE INTAKE MANIFOLD INSULATOR


    1. A004PCM

      Remove the intake manifold insulator from the intake manifold.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A004SCU

      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.

  13. REMOVE DIESEL TURBO PRESSURE SENSOR

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  14. REMOVE NO. 1 GAS FILTER


    1. A004TRD

      Disconnect the vacuum hose.

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

  15. REMOVE GAS FILTER BRACKET


    1. A004PI3

      Remove the 2 bolts and gas filter bracket.

  16. REMOVE ENGINE COVER BRACKET


    1. A004R10

      Remove the bolt and engine cover bracket.

  17. REMOVE NO. 2 INTAKE MANIFOLD


    1. A004Q1O

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

  18. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. A004PIZ

      Disconnect the No. 2 vacuum transmitting hose from the intake manifold.

  19. REMOVE INTAKE MANIFOLD


    1. A004PRNE01
      Text in Illustration
      *1 Nut

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

  20. REPLACE STUD BOLT

    Tech Tips

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


    1. A004TERE01
      *1 16 mm (0.630 in.)
      *2 40 mm (1.57 in.)

      Replace the 2 stud bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }