INTAKE MANIFOLD INSTALLATION

PROCEDURE


  1. INSTALL SWIRL CONTROL VALVE


    1. Install the swirl control valve with the 3 bolts to the intake manifold.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

    2. Attach the rod to the swirl control valve.

  2. INSTALL NO. 2 EGR PIPE


    1. Install a new O-ring to the No. 2 EGR pipe.

    2. Install the No. 2 EGR pip to the intake manifold.

  3. INSTALL EGR GAS TEMPERATURE SENSOR

    Click here

  4. INSTALL GLOW PLUG CONTROLLER ASSEMBLY

    Click here

  5. INSTALL TURBO PRESSURE SENSOR ASSEMBLY

    Click here

  6. INSTALL INTAKE MANIFOLD


    1. Install a new gasket to the No. 2 EGR pipe sub-assembly.

      Tech Tips

      Make sure that the claw of the gasket faces the No. 2 EGR pipe sub-assembly.

    2. Install 4 new gaskets to the intake manifold.

    3. A002PGOE02

      Temporarily install the intake manifold with the 7 bolts.

      Text in Illustration
      A002OPC Bolt A
      A002ODU Bolt B

    4. Step 1:

      Tighten the 5 bolts labeled A of the intake manifold in the order shown in the illustration.

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

    5. Step 2:

      Tighten the 5 bolts labeled A in the order shown in the illustration again.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    6. Step 3:

      Tighten the 2 bolts labeled B.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  7. INSTALL NO. 1 VACUUM PIPE


    1. Install a new O-ring to the No. 1 vacuum pipe.

    2. Using an E7 "TORX" socket wrench, install the No. 1 vacuum pipe with the bolt to the cylinder block sub-assembly.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Connect the vacuum hose.

  8. INSTALL NO. 2 VACUUM HOSE ASSEMBLY


    1. Connect the No. 2 vacuum hose assembly to the No. 1 vacuum pipe.


      1. Check that there is no damage or contamination in the connected part of the No. 1 vacuum pipe.

      2. Line up the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector and push them together until a "click" sound is heard. If the connection is tight, apply a small amount of clean engine oil to the tip of the No. 1 vacuum pipe.

      3. A002OB4

        After connecting the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector, check that the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector are securely connected by pulling on them.

        Text in Illustration
        A002OPC Pull

  9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Using a T25 "TORX" socket wrench, install the engine oil level dipstick guide with the bolt.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

    3. Attach the clamp and connect the fuel feed pipe sub-assembly to the engine oil level dipstick guide.

    4. Install the engine oil level dipstick.

  10. CONNECT ENGINE WIRE


    1. Using a T25 "TORX" socket wrench, connect the engine wire and install the screw.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

    2. Attach the 2 clamps.

    3. Connect the 2 glow plug controller assembly connectors.

    4. Connect the turbo pressure sensor assembly connector.

    5. Connect the camshaft position sensor connector.

    6. Connect the generator assembly connector.

    7. Connect the engine coolant temperature sensor connector.

    8. Connect the fuel pressure sensor connector.

    9. Connect the swirl control valve connector.

    10. Attach the 6 clamps and connect the fuel quantity control valve connector.

    11. Connect the EGR gas temperature sensor connector.

    12. Attach the 2 clamps and connect the glow plug controller assembly harness connector.

  11. INSTALL ENGINE COVER

  12. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  13. INSTALL RADIATOR ASSEMBLY

    Click here

  14. PERFORM SWIRL CONTROL VALVE INITIALIZATION

    Click here