INTAKE MANIFOLD REMOVAL

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 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

    • Injection pipe sub-assembly or supply pump assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Common rail assembly Fuel inlet pipe sub-assembly

    • Injection pipe sub-assembly or supply pump assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly or belt cover sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

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


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE EGR COOLER ASSEMBLY

    Click here

  3. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    A003AVN

    1. Remove the engine oil level dipstick.

    2. Slide the clip and disconnect vacuum hose from the intake manifold.

    3. Remove the bolt and engine oil level dipstick guide.

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

  4. DISCONNECT NO. 2 FUEL PIPE

    A003E9Y

    1. Remove the bolt and disconnect the No. 2 fuel pipe.

  5. REMOVE WIRING HARNESS CLAMP BRACKET

    A003H1M

    1. Disconnect the diesel throttle body assembly connector and pre-stroke control valve connector.

    2. A003DL4

      Detach the 2 wire harness clamps.

    3. Remove the bolt and wiring harness clamp bracket.

  6. REMOVE MANIFOLD STAY

    A003CV7

    1. Remove the bolt and disconnect the wiring harness clamp bracket from the manifold stay.

    2. A003FMA

      Remove the 2 bolts and manifold stay.

  7. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    A003EU8

    1. Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe Click here.

      Text in Illustration
      A003GWQ Union Bolt
      A003G0E Bolt
      A003AH0 Supply Pump Hollow Screw

    2. Remove the bolt from the intake manifold.

    3. Remove the union bolts and gasket from the supply pump assembly.

    4. Remove the supply pump hollow screw and gasket from the supply pump assembly.

  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A003H4AE01
    Text in Illustration
    *a Common Rail Assembly Side
    *b Fuel Supply Pump Assembly Side

    1. Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.

    2. A003BZIE01

      Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.

      SST
      09245-11010

      Note

      If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1 or No. 2 injection clamp with a new one.

    3. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump assembly side.

  9. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    A003D8U

    1. Slide the 2 clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe assembly and common rail assembly.

    2. Slide the 2 clamps and remove the No. 5 fuel hose from the No. 1 nozzle leakage pipe assembly and No. 2 nozzle leakage pipe assembly.

    3. A003EAM

      Slide the clamp and disconnect the No. 6 fuel hose from the No. 3 nozzle leakage pipe assembly.

    4. Remove the 2 bolts and No. 2 nozzle leakage pipe assembly.

  10. REMOVE VACUUM CONTROL VALVE SET

    A003HG2

    1. Disconnect the wire harness clamp and vacuum control valve set connector.

    2. Disconnect the 2 vacuum hoses from the swirl control valve actuator and vacuum transmitting pipe sub-assembly.

    3. Remove the bolt and vacuum control valve set from the intake manifold.

  11. REMOVE INTAKE MANIFOLD


    1. Remove the bolt and disconnect the wire harness bracket.

    2. A003DEH

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

      Text in Illustration
      A003DCD Bolt
      A003GWQ Nut