INTAKE MANIFOLD REMOVAL

PROCEDURE


  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)

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. B001F9W

        w/o EGR System:

        Disconnect the connector.

      2. B001I82

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. B001I1N

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. B001FXJ

      Disconnect the No. 1 vacuum transmitting hose.

    3. B001GI7

      w/ EGR System:

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

    4. B001GEM

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. B001H30E03
      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. B001EGN

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

  12. REMOVE INTAKE PIPE OR HOSE STAY


    1. B001HHH

      Remove the bolt and intake pipe stay.

  13. REMOVE VACUUM CONTROL VALVE SET


    1. B001G5M

      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

    Click here

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  16. REMOVE INTAKE MANIFOLD INSULATOR


    1. B001DLD

      Remove the 2 bolts and intake manifold insulator.

  17. REMOVE INTAKE MANIFOLD


    1. B001HUWE01
      Text in Illustration
      *1 Sensor Wire

      Detach the sensor wire connector clamp from the intake manifold.

    2. B001GOM

      Disconnect the vacuum hose from the intake manifold.

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