INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

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.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  4. REMOVE MANIFOLD STAY

    B003LNE

    1. Remove the 2 bolts and manifold stay from the intake manifold and cylinder block sub-assembly.

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    B003R6V

    1. Remove the engine oil level dipstick.

    2. Remove the bolt and injection pipe clamp.

    3. Remove the bolt and engine oil level dipstick guide.

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

  6. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. B003S17

      Remove the 2 bolts and vacuum switching valve bracket.

  7. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. B003QYE

      Remove the 3 bolts and No. 2 intake air connector bracket from the cylinder head sub-assembly and intake manifold.

  8. REMOVE INTAKE AIR CONNECTOR


    1. Remove the 2 nuts, bolt and intake air connector from the electric EGR control valve assembly.

  9. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  12. REMOVE INTAKE MANIFOLD

    B003MYK

    1. Disconnect the vacuum hose and vacuum switching valve connector from the intake manifold.

    2. Remove the 4 bolts, 2 nuts, intake manifold and gasket.