INTAKE MANIFOLD REMOVAL

PROCEDURE


  1. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  2. REMOVE ENGINE COVER

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  3. DISCONNECT ENGINE WIRE


    1. A01QRVT

      Detach the 2 clamps and disconnect the glow plug controller assembly harness connector.

    2. A01QPBS

      Disconnect the EGR gas temperature sensor connector.

    3. Detach the 6 clamps and disconnect the fuel quantity control valve connector.

    4. A01QOWR

      Disconnect the swirl control valve connector.

    5. Disconnect the fuel pressure sensor connector.

    6. Disconnect the engine coolant temperature sensor connector.

    7. Disconnect the generator assembly connector.

    8. Disconnect the camshaft position sensor connector.

    9. Disconnect the turbo pressure sensor assembly connector.

    10. Disconnect the 2 glow plug controller assembly connectors.

    11. Detach the 2 clamps.

    12. Using a T25 "TORX" socket wrench, remove the screw and disconnect the engine wire.

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01QO92

      Detach the clamp and disconnect the fuel feed pipe sub-assembly from the engine oil level dipstick guide.

    3. Using a T25 "TORX" socket wrench, remove the bolt and engine oil level dipstick guide.

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

  5. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY


    1. A01QS28C01
      *1 No. 1 Vacuum Pipe

      Disconnect the No. 2 vacuum hose assembly from the No. 1 vacuum pipe.


      1. Check that there is no damage or foreign matter on the part of the No. 1 vacuum pipe that contacts the No. 2 vacuum hose assembly connector.

      2. A01QRG4C01
        *a Retainer
        A01QRKS Pinch
        A01QOU0 Pull out

        If the No. 2 vacuum hose assembly connector and No. 1 vacuum pipe are stuck together, hold the No. 1 vacuum pipe by hand and push and pull on the No. 2 vacuum hose assembly connector.

        Note


        • Check for any dirt and foreign matter in the No. 1 vacuum pipe and around the No. 2 vacuum hose assembly connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

        • Do not use any tools to separate the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

        • Check for any dirt and foreign matter on the No. 1 vacuum pipe seal surface. Clean if necessary.

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the No. 2 vacuum hose assembly.

        • If the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector are stuck together, pinch the No. 2 vacuum hose assembly connector between your fingers and turn it carefully to free it. Then disconnect the No. 2 vacuum hose assembly.

      3. Check for dirt or mud on the No. 1 vacuum pipe seal surface of the disconnected No. 1 vacuum pipe. Clean if necessary.

      4. To protect the disconnected No. 1 vacuum pipe and No. 2 vacuum hose assembly connector from damage and contamination, cover them with a plastic bag and tape.

  6. REMOVE NO. 1 VACUUM PIPE


    1. A01QT46

      Disconnect the vacuum hose.

    2. Using an E7 "TORX" socket wrench, remove the bolt and No. 1 vacuum pipe from the cylinder block sub-assembly.

    3. Remove the O-ring from the No. 1 vacuum pipe.

  7. REMOVE INTAKE MANIFOLD


    1. A01QP1EC01
      A01QRKS Bolt (A)
      A01QOU0 Bolt (B)

      Remove the bolt (B) and loosen the 6 bolts (A) in the order shown in the illustration, and then remove the intake manifold.

      Tech Tips

      The bolts (A) in the illustration cannot be removed from the intake manifold.

    2. A01QU2X

      Remove the 4 gaskets from the intake manifold.

    3. Remove the gasket from the No. 2 EGR pipe.

  8. REMOVE TURBO PRESSURE SENSOR

    Click here

  9. REMOVE GLOW PLUG CONTROLLER ASSEMBLY

    Click here

  10. REMOVE EGR GAS TEMPERATURE SENSOR

    Click here

  11. REMOVE NO. 2 EGR PIPE


    1. A01QPKU

      Remove the No. 2 EGR pipe from the intake manifold.

    2. A01QPI0C01
      *1 O-ring

      Remove the O-ring from the No. 2 EGR pipe.

  12. REMOVE SWIRL CONTROL VALVE


    1. A01QOR7C01
      *a Rod

      Detach the rod from the swirl control valve.

    2. Remove the 3 bolts and swirl control valve from the intake manifold.