INTAKE MANIFOLD REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the injector assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Battery terminal is disconnected/reconnected Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes) Stop and start system

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Memorize steering angle neutral point Pre-collision system

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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. 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 (w/ EGR System with EGR Cooler)

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  4. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

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  5. REMOVE EGR VALVE ADAPTER (w/o EGR Cooler)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0068KZ

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B0068SP

      w/ EGR System:


      1. Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

      2. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the EGR valve adapter.

    3. B0068WM

      w/o EGR System:

      Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the EGR valve adapter.

    4. B0068P7

      w/ EGR System:


      1. Slide the clamp and disconnect the No. 7 water by-pass hose from the EGR pipe stay.

      2. Slide the clamp and disconnect the water hose from the EGR valve adapter.

      3. Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

    5. B0068V7

      w/o EGR System:


      1. Slide the clamp and disconnect the No. 7 water by-pass hose from the EGR pipe stay.

      2. Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

    6. B0069F2

      w/ EGR System:

      Remove the 4 nuts, bolt and No. 1 EGR pipe sub-assembly from the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

    7. B0068JS

      w/ EGR System:

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

    8. Remove the 3 bolts and EGR valve adapter from the intake manifold.

      B0068FHC02
      *A w/ EGR System *B w/o EGR System
    9. B0068UJ

      Remove the 2 bolts and EGR pipe stay from the EGR valve adapter.

  6. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B0068ZB

      w/ DPF and No. 2 Fuel Pipe Clamp:

      Detach the No. 2 fuel pipe clamp from the engine oil level dipstick guide.

    2. Remove the engine oil level dipstick.

    3. Disconnect the vacuum hose from the intake manifold.

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

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

  7. DISCONNECT NO. 2 FUEL PIPE


    1. B0069E4

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

  8. 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.

  9. 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.

  10. 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.

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    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.

  11. REMOVE NO. 3 FUEL PIPE (w/ DPF or Pressurized Fuel Filter)


    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.

  12. 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.

  13. 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.

  14. REMOVE INTAKE MANIFOLD


    1. B006903

      Remove the bolt and disconnect the wire harness bracket.

    2. B006951

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

    3. B00691KC01
      B0068HS Bolt
      B006964 Nut

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