INTAKE MANIFOLD INSTALLATION

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

INSTALL INTAKE MANIFOLD
1. Text in Illustration
  
  *1 Protrusion
  
  Rear side
  
  Install a new gasket to the cylinder head sub-assembly.
  
  Tech Tips
  
  Install the gasket with the protrusion the rear side of the vehicle as shown in the illustration.
2. Temporarily install the intake manifold with the 7 bolts and 2 nuts.
3. Tighten the 7 bolts and 2 nuts in the order shown in the illustration.
  
  Text in Illustration
  
  Bolt
  
  Nut
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
4. Connect the wire harness bracket A, B and C with the bolt.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
INSTALL VACUUM CONTROL VALVE SET
1. Install the vacuum control valve set with bolt to the cylinder head sub-assembly.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 2 vacuum hoses to the swirl control valve actuator and vacuum transmitting pipe subassembly.
3. Connect the wire harness clamp and vacuum control valve set connector.
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. Install the No. 2 nozzle leakage pipe assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the No. 6 fuel hose to the No. 3 nozzle leakage pipe assembly and slide the clamp to secure the hoses.
3. Install the No. 4 fuel hose and No. 5 fuel hose to the No. 2 nozzle leakage pipe assembly, and slide the 4 clamps to secure the hose.
INSTALL FUEL INLET PIPE SUB-ASSEMBLY

Note

When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe subassembly, No. 1 injection pipe clamp and No. 2 injection pipe clamp with a new one. Keep the fuel inlet pipe sub-assembly free of foreign matter.
1. Temporarily install the fuel inlet pipe sub-assembly.
2. Install new No. 1 injection pipe clamp and No. 2 injection pipe clamp with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using SST, tighten the fuel inlet pipe sub-assembly union nut on the common rail side sub-assembly.
  
  SST
  
  09245-11010
  
  Torque:
  
  Specified tightening torque
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
  - When using a union nut wrench (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)
4. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using a 19 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply pump assembly side.
  
  Torque:
  
  Specified tightening torque
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
  - When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 41 N*m (418 kgf*cm, 30 ft.*lbf)

Text in Illustration
*1	Protrusion
	Rear side

Text in Illustration
	Bolt
	Nut

INSTALL NO. 3 FUEL PIPE

Temporarily install the No. 3 fuel pipe and 2 new gaskets with the union bolt and supply pump hollow screw.
Tighten the union bolt and supply pump hollow screw.

Torque:

42 N*m { 428 kgf*cm, 31 ft.*lbf }

Text in Illustration
*a	Torque Wrench Fulcrum Length
*b	0 to 2 mm (0 to 0.787 in.)

Install the 2 fuel pipe clamps to the No. 3 fuel pipe and fuel filter.

INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY
1. Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.
2. Text in Illustration
  
  Union Bolt
  
  Bolt
  
  Tighten the 2 union bolts and bolts in the order shown in the illustration.
  
  Torque:
  
  union bolt
  
  42 N*m { 428 kgf*cm, 31 ft.*lbf }
  
  bolt
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe Click here.
INSTALL MANIFOLD STAY
1. Install the manifold stay with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Install the wiring harness clamp bracket with the bolt.
  
  Torque:
  
  13 N*m { 128 kgf*cm, 9 ft.*lbf }
INSTALL WIRING HARNESS CLAMP BRACKET
1. Install the wiring harness clamp bracket with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Attach the 2 wire harness clamps.
3. Connect the diesel throttle body assembly connector and pre-stroke control valve connector.
INSTALL NO. 2 FUEL PIPE
1. Connect the No. 2 fuel pipe and with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the engine oil level dipstick guide.
3. Install the engine oil level dipstick guide with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Connect the vacuum hose to the intake manifold.
5. Install the engine oil level dipstick.
INSTALL EGR COOLER ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Click here
BLEED AIR FROM FUEL SYSTEM

Click here