INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head, or intake manifold, it is necessary to replace the injection pipes with new ones.

  • w/ DPF:

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. PRECAUTION

    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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. DRAIN ENGINE COOLANT

    Click here

  8. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. B001W0W

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  10. REMOVE NO. 1 AIR CLEANER HOSE


    1. B001W91

      Loosen the hose clamp and remove the No. 1 air cleaner hose.

  11. REMOVE INTAKE AIR CONNECTOR


    1. B001ZP1E06
      Text in Illustration
      *A w/ Viscous Heater

      w/ Viscous Heater:

      Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    2. w/o Viscous Heater:

      Disconnect the connector from the water temperature sensor.

    3. Using a clip remover, detach the 3 wire harness clamps.

    4. B001YA6

      Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

  12. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)


    1. B001WRB

      Loosen the No. 1 air hose clamp.

    2. Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

    3. B001VNY

      Remove the 3 nuts, bolt and No. 1 cool air inlet.

    4. Remove the gasket from the air tube RH.

  13. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    1. B001XWF

      Loosen the No. 2 air hose clamp.

    2. B00205B

      Remove the 3 nuts, bolt and No. 2 cool air inlet.

    3. Remove the gasket from the air tube LH.

  14. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B001WWD

      Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

    2. B001YSWE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the ventilation hose from the cylinder head cover RH.

    3. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

    4. Remove the O-ring from the No. 2 engine oil level dipstick guide.

  15. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  16. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  17. DRAIN CLUTCH FLUID (for Manual Transmission)

  18. REMOVE CLUTCH HOSE (for Manual Transmission)

    Click here

  19. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  20. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

    Click here

  21. REMOVE NO. 1 GAS FILTER

    Click here

  22. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  23. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  24. REMOVE NO. 1 AIR HOSE


    1. B001XUW

      Loosen the hose clamp and remove the No. 1 air hose.

  25. REMOVE NO. 3 AIR TUBE


    1. B001YM1

      Disconnect the wire harness from the clamp.

    2. Remove the nut and ground wire.

    3. B001WBZ

      Remove the bolt and disconnect the wire harness bracket.

    4. B001ZFA

      Loosen the hose clamp and remove the bolt and No. 3 air tube.

  26. REMOVE NO. 2 AIR HOSE


    1. B001XT6

      Loosen the hose clamp and remove the No. 2 air hose.

  27. REMOVE NO. 4 AIR TUBE


    1. B001XO8

      Remove the bolt and disconnect the suction hose.

    2. B001Y7X

      Loosen the hose clamp and remove the bolt and No. 4 air tube.

  28. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


    1. B001Z26

      Disconnect the ventilation hose from the oil separator.

    2. Loosen the hose clamp.

    3. Remove the bolt and No. 2 air cleaner pipe.

  29. DISCONNECT WATER HOSE SUB-ASSEMBLY

    B001WR0E01
    Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater

  30. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    1. B001WX4

      Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

  31. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. B001X7U

      Loosen the hose clamp.

    2. Remove the bolt and No. 1 air cleaner pipe.

  32. DISCONNECT FUEL HOSE


    1. B001ZZEE02
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/ DPF:

    2. B001XB0E02
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/o DPF:

  33. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)


    1. B001XKK

      Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

  34. REMOVE NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. Remove the 2 bolts and nut.

        B001YFGE01
        Text in Illustration
        *A w/ DPF *B w/o DPF

      2. w/ DPF:

        Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

      3. w/o DPF:

        Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.

    2. w/o EGR System:


      1. B001XKG

        Remove the 2 bolts and nut.

      2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

  35. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. B001YAG

        Disconnect the 4 connectors.

      2. Using a clip remover, detach the 3 wire harness clamps.

      3. B001VWP

        Disconnect the 2 connectors.

      4. Using a clip remover, detach the 3 wire harness clamps.

      5. Disconnect the 8 connectors.

        B001VWHE03
        Text in Illustration
        *A w/ DPF *B w/o DPF

      6. Remove the bolt and engine wire harness bracket labeled B.

      7. Using a clip remover, detach the wire harness clamp labeled D.

      8. Remove the 2 bolts and disconnect the engine wire protector labeled A.

      9. for RHD:

        Disconnect the wire harness from the wire harness clamp holder labeled C.

    2. RH Side:


      1. Disconnect the 7 connectors.

        B001WECE03
        Text in Illustration
        *A w/ DPF *B w/o DPF

      2. Using a clip remover, detach the wire harness clamp.

      3. Remove the 3 bolts and disconnect the wire harness protector labeled A.

      4. Remove the bolt and wire harness bracket labeled B.

      5. Remove the screw grommet, nut and glow plug wire harness labeled C.

      6. B001YY6E05
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

      7. for RHD:

        Remove the bolt and wire harness clamp holder.

    3. Rear Side:


      1. B001XVJE03
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        Using a clip remover, detach the wire harness clamp.

      2. Remove the 2 bolts and 2 ground wires labeled C.

      3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

      4. w/ DPF:

        Disconnect the 3 connectors.

      5. w/o DPF:

        Disconnect the connector.

      6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.

  36. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Note


    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.

    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.


    1. B001YAV

      Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

    2. Remove the bolt and No. 2 injection pipe clamp.

    3. Remove the union bolt and gasket.

    4. Remove the bolt, nut and No. 2 fuel pipe.

  37. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.


    1. w/ EGR System:


      1. B001ZN5

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

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

      3. Remove the No. 6 injection pipe.

    2. w/o EGR System:


      1. B001X8U

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the nut and No. 2 injection pipe clamp.

      3. Remove the bolt and No. 6 injection pipe.

  38. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

    Click here

  39. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  40. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)

    Click here

  41. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. B001YJO

      Disconnect the fuel hose.

    2. Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

  42. REMOVE INJECTION PIPE LH


    1. B001XXSE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. B001XTSE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  43. REMOVE NO. 2 FUEL PIPE (w/ DPF)

    Click here

  44. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  45. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

  46. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


    1. w/ DPF:


      1. B001ZW1

        Remove the bolt and No. 2 injection pipe clamp.

      2. Disconnect the fuel hose.

      3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.

    2. w/o DPF:


      1. B001XR7

        Disconnect the 2 hoses from the fuel pipe.

      2. Remove the bolt and fuel filter to injection pump fuel pipe.

  47. DISCONNECT FUEL PUMP MOTOR WIRE


    1. B001XHL

      Remove the bolt and disconnect the connector from the fuel supply pump.

  48. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY


    1. B00207I

      Using a union nut wrench, remove the No. 5 injection pipe.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.

  49. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)

    Click here

  50. REMOVE NO. 2 FUEL INJECTOR PROTECTOR (w/ DPF)

    Click here

  51. REMOVE NO. 1 FUEL INJECTOR PROTECTOR (w/ DPF)

    Click here

  52. REMOVE INJECTION PIPE RH


    1. B001Z57E03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. B001ZK3E03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  53. REMOVE COMMON RAIL ASSEMBLY RH

    Click here

  54. REMOVE CONNECTING WIRE (w/ DPF)


    1. B001Z27

      Detach the 2 clamps and remove the connecting wire.

  55. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. B001WWB

      Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

  56. REMOVE NO. 2 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  57. REMOVE NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  58. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    B00206A

  59. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    B001WBL

  60. REMOVE INTAKE PIPE


    1. B001Y0M

      w/ EGR System:

      Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

    2. B001XI0

      w/o EGR System:

      Remove the 2 nuts, 4 bolts, intake pipe and gasket.

  61. DISCONNECT NO. 2 ENGINE WIRE


    1. B001XPM

      Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

  62. REMOVE NO. 3 INTAKE MANIFOLD


    1. B001YG1

      Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

  63. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

    B001Z62

  64. REMOVE EGR PIPE INSULATOR (w/ EGR System)


    1. B001YPI

      Remove the 2 bolts and EGR pipe insulator.

  65. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)


    1. B001ZT9

      Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

    2. B001X9V

      Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

  66. REMOVE EGR COOLER INSULATOR (w/ EGR System)

    B001WF3

  67. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)


    1. B001WZQ

      Disconnect the No. 1 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

      Note

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  68. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)


    1. B001YS8

      Disconnect the No. 2 fuel hose from the fuel cooler.

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

      Note

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  69. DISCONNECT NO. 6 WATER BY-PASS HOSE (w/o DPF)

    B001Y1K

  70. REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

    Click here

  71. REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)


    1. B001XY2

      Disconnect the 3 fuel tube connectors Click here.

    2. Detach the 3 clamps and remove the fuel tube.

  72. REMOVE NO. 1 WATER BY-PASS PIPE


    1. B001WCVE04
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

  73. REMOVE FUEL HOSE BRACKET (w/ DPF)


    1. B001Z9K

      Remove the bolt and fuel hose bracket.

  74. REMOVE NO. 1 FUEL PIPE CLAMP (w/ DPF)


    1. B001WKME03
      Text in Illustration
      *a RH Side
      *b LH Side

      Remove the 2 bolts and 2 No. 1 fuel pipe clamps.

  75. REMOVE NO. 1 INTAKE MANIFOLD


    1. B001ZVN

      Remove the 9 bolts, No. 1 intake manifold and gasket.

  76. REMOVE NO. 2 INTAKE MANIFOLD


    1. B001ZUJ

      Remove the 9 bolts, No. 2 intake manifold and gasket.

  77. REPLACE STUD BOLT

    Tech Tips

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


    1. B001Y8NE04
      *1 20 mm (0.787 in.)
      *2 42 mm (1.65 in.)
      *3 13 mm (0.512 in.)

      For Intake Pipe:

      Using an E8 "TORX" wrench, replace the stud bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. For No. 3 Intake Manifold:

      B002075E01

      1. Using an E8 "TORX" wrench, replace the stud bolts labeled A.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Using an E6 "TORX" wrench, replace the stud bolts labeled B.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      3. Using an E6 "TORX" wrench, replace the stud bolt labeled C.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  78. REPLACE RING PIN

    Tech Tips

    It is not necessary to remove a ring pin unless it is being replaced.


    1. B001XRJE02
      Text in Illustration
      *1 Protrusion height

      For No. 1 and No. 2 Intake Manifold:

      Replace the ring pins.

      Standard protrusion
      4.4 to 5.6 mm (0.173 to 0.222 in.)