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 and/or fuel inlet pipe sub-assembly with new ones.

    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

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    		 Fuel inlet pipe sub-assembly

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

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 EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B0068HNC01
      *A w/ DPF
      *B w/o DPF

      Remove the engine oil level dipstick.

    2. Disconnect the vacuum hose from the intake manifold.

    3. 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 FUEL PIPE


    1. B0069E4

      Remove the bolt and disconnect the No. 2 fuel pipe.

  6. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B0068NN

      Disconnect the diesel throttle body assembly connector and pre-stroke control valve connector.

    2. B0068ZV

      Detach the 2 wire harness clamps.

    3. Remove the bolt and wiring harness clamp bracket.

  7. REMOVE MANIFOLD STAY


    1. B0068T5

      Remove the bolt and disconnect the wiring harness clamp bracket from the intake manifold stay.

    2. B0068B3

      Remove the 2 bolts and manifold stay.

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)


    1. B00694RC02
      B006964 Union Bolt
      B0069AV Bolt

      Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe.

      Click here

    2. Remove the bolt from the intake manifold.

    3. Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.

  9. REMOVE NO. 3 FUEL PIPE (w/ DPF)


    1. B00693BC01
      B0068HS Union Bolt
      B006964 Supply Pump Hollow Screw

      Remove the union bolts, supply pump hollow screw and 2 gaskets from the supply pump assembly and fuel filter.

    2. Remove the 2 fuel pipe clamps from the No. 3 fuel pipe and fuel filter.

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. B0069FSC01
      *a Common Rail Assembly Side
      *b Fuel Supply Pump Assembly Side

      Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.

    2. B006947E01

      Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.

      Note

      If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1 or No. 2 injection clamp with a new one.

    3. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump assembly side.

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B0068XR

      Slide the clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe assembly and common rail assembly.

    2. Slide the 2 clamps and remove the No. 5 fuel hose from the No. 1 nozzle leakage pipe assembly and No. 2 nozzle leakage pipe assembly.

    3. B00699T

      Slide the clamp and disconnect the No. 6 fuel hose from the No. 3 nozzle leakage pipe assembly.

    4. Remove the 2 bolts and No. 2 nozzle leakage pipe assembly.

  12. REMOVE VACUUM CONTROL VALVE SET (w/ DPF)

    B0068TG

    1. Disconnect the wire harness clamp and vacuum control valve set connector.

    2. Disconnect the 2 vacuum hoses from the vacuum control valve set and vacuum transmitting pipe sub-assembly.

    3. Remove the bolt and vacuum control valve set from the intake manifold.

  13. REMOVE INTAKE MANIFOLD


    1. Remove the bolt and disconnect the wire harness bracket.

    2. B006951

      w/o DPF:

      Disconnect the vacuum hose from the vacuum transmitting pipe sub-assembly.

    3. B00699IC01
      *A w/ DPF
      *B w/o DPF
      B0068HS Bolt
      B006964 Nut

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