INTAKE MANIFOLD INSTALLATION

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. INSTALL INTAKE MANIFOLD


    1. A004N9YE02

      Install a new gasket to the cylinder head.

      Tech Tips

      Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

    2. A004O0JE02
      Text in Illustration
      *1 Nut

      Install the intake manifold with the 7 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      Bolt Length
      Item Specified Condition
      Bolt A 90 mm (3.54 in.)
      Bolt B 25 mm (0.984 in.)

  2. CONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. Connect the No. 2 vacuum transmitting hose to the intake manifold.

  3. INSTALL NO. 2 INTAKE MANIFOLD


    1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  4. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  5. INSTALL GAS FILTER BRACKET


    1. Install the gas filter bracket with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  6. INSTALL NO. 1 GAS FILTER


    1. A004NFEE04
      Text in Illustration
      *1 Protrusion
      *2 Groove

      Install the No. 1 gas filter to the gas filter bracket.

      Note

      Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.

    2. Connect the vacuum hose.

  7. INSTALL DIESEL TURBO PRESSURE SENSOR

    Click here

  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    3. Connect the connector and attach the wire harness clamp to the engine oil level dipstick guide.

    4. Install the engine oil level dipstick.

  9. INSTALL INTAKE MANIFOLD INSULATOR


    1. Install the intake manifold insulator to the intake manifold.

  10. INSTALL COMMON RAIL ASSEMBLY

    Click here

  11. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Click here

  12. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  13. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  14. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  15. CONNECT NO. 8 WATER BY-PASS HOSE

  16. INSTALL NO. 7 WATER BY-PASS HOSE

  17. INSTALL EGR VALVE BRACKET

    Click here

  18. CONNECT ENGINE WIRE

    Click here

  19. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  20. BLEED AIR FROM FUEL SYSTEM

    Click here

  21. INSPECT FOR FUEL LEAK

    Click here