INTAKE MANIFOLD INSTALLATION

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)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-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. INSTALL INTAKE MANIFOLD


    1. B0068ODC01
      *a Protrusion

      Install a new gasket to the cylinder head sub-assembly.

      Tech Tips

      Install the gasket with the protrusion the rear side of the vehicle as shown in the illustration.

    2. Temporarily install the intake manifold with the 7 bolts and 2 nuts.

    3. B00691KC02
      B0068HS Bolt
      B006964 Nut

      Tighten the 7 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    4. Connect the vacuum hose assembly to the vacuum transmitting pipe sub-assembly.

    5. Connect the wire harness bracket with the bolt.

      Torque:
      18.6 N*m  { 190 kgf*cm, 14 ft.*lbf }

  2. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Install the No. 2 nozzle leakage pipe assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the No. 6 fuel hose to the No. 3 nozzle leakage pipe assembly and slide the clamp to secure the hoses.

    3. Install the No. 4 fuel hose and No. 5 fuel hose to the No. 2 nozzle leakage pipe assembly, and slide the 4 clamps to secure the hose.

  3. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note

    When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe sub-assembly, No. 1 injection pipe clamp and No. 2 injection pipe clamp with a new one.

    Keep the fuel inlet pipe sub-assembly free of foreign matter.


    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. Install new No. 1 injection pipe clamp and No. 2 injection pipe clamp with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B006947E01

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

      SST
      09245-11010
      Torque:
      Specified tightening torque
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)

    4. B0068F6C06
      *a Torque Wrench Fulcrum Length

      Using a 19 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply pump assembly side.

      Torque:
      Specified tightening torque
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 41 N*m (418 kgf*cm, 30 ft.*lbf)

  4. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Install the wiring harness clamp bracket with the bolt.

      Torque:
      12.6 N*m  { 128 kgf*cm, 9 ft.*lbf }

  5. INSTALL NO. 3 FUEL PIPE (w/ DPF or Pressurized Fuel Filter)


    1. Temporarily install the No. 3 fuel pipe and 2 new gaskets with the union bolt and supply pump hollow screw.

    2. Tighten the union bolt and supply pump hollow screw.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
    3. B0068QJC03
      *a Paint Mark
      *b 0 to 2 mm (0 to 0.0787 in.)

      Install the fuel pipe clamp to the fuel filter assembly and No. 3 fuel pipe.

      Note

      Be careful that the fuel pipe clamp and No. 4 fuel pipe sub-assembly do not interfere with each other.

      Tech Tips

      Make sure the fuel pipe clamp is oriented as shown in the illustration.

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)


    1. Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.

    2. B00694RC03
      B006964 Union Bolt
      B0069AV Bolt

      Tighten the 2 union bolts and bolts in the order shown in the illustration.

      Torque:
      for union bolt
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe.

      Click here

  7. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Attach the 2 wire harness clamps.

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

  8. INSTALL NO. 2 FUEL PIPE


    1. Connect the No. 2 fuel pipe and with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Connect the vacuum hose to the intake manifold.

    5. Install the engine oil level dipstick.

    6. w/ DPF and No. 2 Fuel Pipe Clamp:

      Attach the No. 2 fuel pipe clamp to the engine oil level dipstick guide.

  10. INSTALL EGR VALVE ADAPTER (w/o EGR Cooler)


    1. B0068UJ

      Install the EGR pipe stay to the EGR valve adapter with the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Temporarily install the EGR valve adapter to the intake manifold with the 4 bolts.

    3. Tighten the 4 bolts in the order shown in the illustration.

      Note

      Make sure to tighten the bolts in the correct order.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      B0068FHC01
      *A w/ EGR System *B w/o EGR System

    4. w/ EGR System:

      Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    5. w/ EGR System:

      Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly with the bolt and 4 new nuts.

      Torque:
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for nut
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    6. w/ EGR System:


      1. Connect the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Connect the water hose to the EGR valve adapter, and slide the clamp to secure the hose.

      3. Connect the No. 7 water by-pass hose to the EGR pipe stay, and slide the clamp to secure the hose.

    7. w/o EGR System:


      1. Connect the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Connect the No. 7 water by-pass hose to the EGR pipe stay, and slide the clamp to secure the hose.

    8. w/ EGR System:


      1. Install the No. 3 water by-pass pipe sub-assembly to the EGR valve adapter with the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

    9. w/o EGR System:

      Install the No. 3 water by-pass pipe sub-assembly to the EGR valve adapter with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    10. Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.

  11. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  12. INSTALL EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  14. ADD ENGINE COOLANT

    Click here

  15. BLEED AIR FROM FUEL SYSTEM

    Click here

  16. INSPECT FOR FUEL LEAK

    Click here

  17. INSPECT FOR COOLANT LEAK

    Click here

  18. INSPECT FOR OIL LEAK

    Click here

  19. INSPECT ENGINE OIL LEVEL

    Click here