INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

Note


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

  • When replacing the supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  2. SEPARATE ENGINE WIRE

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  3. REMOVE EGR VALVE BRACKET

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  4. DISCONNECT NO. 7 WATER BY-PASS HOSE

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  5. DISCONNECT NO. 8 WATER BY-PASS HOSE

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  6. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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  7. REMOVE EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

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  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  9. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  10. REMOVE COMMON RAIL ASSEMBLY

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  11. REMOVE INTAKE MANIFOLD INSULATOR


    1. A012ILA

      Remove the intake manifold insulator from the intake manifold.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A012M25

      Disconnect the connector, and then the wire harness clamp from the engine oil level dipstick guide.

    3. Remove the 2 bolts and engine oil level dipstick guide.

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

  13. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR (DIESEL TURBO PRESSURE SENSOR)

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  14. REMOVE NO. 1 GAS FILTER


    1. A012MUX

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  15. REMOVE GAS FILTER BRACKET


    1. A012MG7

      Remove the 2 bolts and gas filter bracket.

  16. REMOVE ENGINE COVER BRACKET


    1. A012H8X

      Remove the bolt and engine cover bracket.

  17. REMOVE NO. 2 INTAKE MANIFOLD


    1. A012KM8

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  18. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. A012F8H

      Slide the clip and disconnect the No. 2 vacuum transmitting hose from the intake manifold.

  19. REMOVE INTAKE MANIFOLD


    1. A012MAZC01
      A012M0O Bolt
      A012L0C Nut

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

    2. Remove the gasket from the cylinder head.

  20. REMOVE STUD BOLT

    Tech Tips

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


    1. A012MM8

      Remove the 2 stud bolts.