INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

Note


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

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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  4. DISCONNECT ENGINE WIRE

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  5. REMOVE EGR VALVE BRACKET

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  6. REMOVE NO. 7 WATER BY-PASS HOSE


    1. A01VA7R

      Slide the clamp and remove the No. 7 water by-pass hose from the electric EGR control valve assembly.

  7. DISCONNECT NO. 8 WATER BY-PASS HOSE

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  8. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

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  9. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

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  11. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  12. REMOVE COMMON RAIL ASSEMBLY

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  13. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01V6UU

      Remove the intake manifold insulator from the intake manifold.

  14. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01V9O3

      Disconnect the connector and detach 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.

  15. REMOVE DIESEL TURBO PRESSURE SENSOR

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  16. REMOVE NO. 1 GAS FILTER


    1. A01VAWU

      Disconnect the vacuum hose.

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

  17. REMOVE GAS FILTER BRACKET


    1. A01V86Q

      Remove the 2 bolts and gas filter bracket.

  18. REMOVE ENGINE COVER BRACKET


    1. A01V9XV

      Remove the bolt and engine cover bracket.

  19. REMOVE NO. 2 INTAKE MANIFOLD


    1. A01VAS6

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

  20. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01V84X

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

  21. REMOVE INTAKE MANIFOLD


    1. A01V95QC02
      *1 Nut

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

  22. REMOVE STUD BOLT

    Tech Tips

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