INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, 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

    • 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.

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 EGR COOLER ASSEMBLY

    Click here

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    B001CLV

    1. Remove the engine oil level dipstick.

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

    3. Remove the O-ring from the engine oil level dipstick guide.

  5. DISCONNECT NO. 2 FUEL PIPE

    B001E3A

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

  6. REMOVE WIRING HARNESS CLAMP BRACKET

    B001CH8

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

    2. B001HWG

      Detach the 2 wire harness clamps.

    3. Remove the bolt and wiring harness clamp bracket.

  7. REMOVE MANIFOLD STAY

    B001GMF

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

    2. B001G43

      Remove the 2 bolts and manifold stay.

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    B001H36
    Text in Illustration
    B001DEF Union Bolt
    B001HIB Bolt

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

    2. Remove the bolt from the intake manifold.

    3. Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.

  9. REMOVE NO. 3 FUEL PIPE

    B001GGB
    Text in Illustration
    B001CHY Union Bolt
    B001DEF Supply Pump Hollow Screw

    1. Remove the union bolts, supply pump hollow screw and 2 gaskets from the supply pump assembly and fuel filter.

    2. Remove the 2 fuel pipe clamps from the No. 3 fuel pipe and fuel filter.

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    B001DKTE02
    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. B001FMEE01

      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.

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    B001DS4

    1. Slide the 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. B001FUV

      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.

  12. REMOVE VACUUM CONTROL VALVE SET

    B001CWK

    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.

  13. REMOVE INTAKE MANIFOLD

    B001G3E

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

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