INTAKE MANIFOLD REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head, or intake manifold, it is necessary to replace the injection pipes with new ones.

  • w/ DPF:

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.


  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 FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. A015DL0

      Remove the 3 bolts and screw.

    2. Loosen the clip and remove the front fender splash shield LH.

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Remove the 3 bolts and 2 screws.

    2. Loosen the clip and remove the front fender splash shield RH.

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover.

  6. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 7 clips and upper radiator support seal.

  7. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Collect the coolant in a container and dispose of it according to the regulations in your area.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator reservoir cap to drain the coolant in the radiator.

    3. Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

      A015DKUE01
    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  8. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0159QI

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  10. REMOVE NO. 1 AIR CLEANER HOSE


    1. A015DGT

      Loosen the hose clamp and remove the No. 1 air cleaner hose.

  11. REMOVE INTAKE AIR CONNECTOR


    1. A015852E04
      Text in Illustration
      *A w/ Viscous Heater

      w/ Viscous Heater:

      Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    2. w/o Viscous Heater:

      Disconnect the connector from the water temperature sensor.

    3. Using a clip remover, detach the 3 wire harness clamps.

    4. A015DJJ

      Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

  12. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)


    1. A015E40

      Loosen the No. 1 air hose clamp.

    2. Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

    3. A0158C6

      Remove the 3 nuts, bolt and No. 1 cool air inlet.

    4. Remove the gasket from the air tube RH.

  13. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015B0X

      Loosen the No. 2 air hose clamp.

    2. A015A93

      Remove the 3 nuts, bolt and No. 2 cool air inlet.

    3. Remove the gasket from the air tube LH.

  14. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0156LC

      Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

    2. A015C0GE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the ventilation hose from the cylinder head cover RH.

    3. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

    4. Remove the O-ring from the No. 2 engine oil level dipstick guide.

  15. REMOVE AIR TUBE SUB-ASSEMBLY RH


    1. A0155DE

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  16. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH


    1. A0159VX

      Disconnect the throttle position sensor connector.

    2. Disconnect the throttle motor connector.

    3. Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket from the intake pipe.

  17. DRAIN CLUTCH FLUID (for Manual Transmission)

  18. REMOVE CLUTCH HOSE (for Manual Transmission)


    1. A015C2Z

      Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

      Note


      • Do not bend or damage the flexible hose tubes.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

    2. Remove the 2 clips.

    3. A0159T9

      Remove the bolt and clutch hose.

  19. REMOVE AIR TUBE SUB-ASSEMBLY LH


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  20. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. A015APM

      Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

      Note


      • Do not bend or damage the flexible hose tube.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.

    2. A0155T9

      Remove the 2 bolts and tube connector to flexible hose tube.

  21. REMOVE NO. 1 GAS FILTER


    1. A01591S

      Disconnect the hose from the intake pipe.

    2. Remove the No. 1 gas filter.

  22. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. A0156KS

      for Manual Transmission:


      1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.

    2. A0157EZ

      Remove the 2 bolts and No. 3 intercooler support bracket.

  23. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH


    1. A015A91

      Disconnect the throttle position sensor connector.

    2. Disconnect the throttle motor connector.

    3. Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket from the intake pipe.

  24. REMOVE NO. 1 AIR HOSE


    1. A0158SB

      Loosen the hose clamp and remove the No. 1 air hose.

  25. REMOVE NO. 3 AIR TUBE


    1. A0159U8

      Disconnect the wire harness from the clamp.

    2. Remove the nut and ground wire.

    3. A0155HD

      Remove the bolt and disconnect the wire harness bracket.

    4. A01572L

      Loosen the hose clamp and remove the bolt and No. 3 air tube.

  26. REMOVE NO. 2 AIR HOSE


    1. A0155DS

      Loosen the hose clamp and remove the No. 2 air hose.

  27. REMOVE NO. 4 AIR TUBE


    1. A015A8F

      Remove the bolt and disconnect the suction hose.

    2. A015577

      Loosen the hose clamp and remove the bolt and No. 4 air tube.

  28. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015AEL

      Disconnect the ventilation hose from the oil separator.

    2. Loosen the hose clamp.

    3. Remove the bolt and No. 2 air cleaner pipe.

  29. DISCONNECT WATER HOSE SUB-ASSEMBLY

    A015CADE02
    Text in Illustration
    *A w/ Rear Heater
    *B w/o Rear Heater
  30. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    1. A0158HY

      Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

  31. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015D8F

      Loosen the hose clamp.

    2. Remove the bolt and No. 1 air cleaner pipe.

  32. DISCONNECT FUEL HOSE


    1. A0159B1E01
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/ DPF:

    2. A0159IIE01
      Text in Illustration
      *a for Fuel Filter with Heater
      *b for Fuel Filter without Heater

      w/o DPF:

  33. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)


    1. A015DM6

      Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

  34. REMOVE NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. Remove the 2 bolts and nut.

        A0157IQE01
        Text in Illustration
        *A w/ DPF *B w/o DPF
      2. w/ DPF:

        Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

      3. w/o DPF:

        Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.

    2. w/o EGR System:


      1. A0157AC

        Remove the 2 bolts and nut.

      2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

  35. DISCONNECT ENGINE WIRE


    1. LH Side:


      1. A015D5V

        Disconnect the 4 connectors.

      2. Using a clip remover, detach the 3 wire harness clamps.

      3. A015AFR

        Disconnect the 2 connectors.

      4. Using a clip remover, detach the 3 wire harness clamps.

      5. Disconnect the 8 connectors.

        A015AYBE01
        Text in Illustration
        *A w/ DPF *B w/o DPF
      6. Remove the bolt and engine wire harness bracket labeled B.

      7. Using a clip remover, detach the wire harness clamp labeled D.

      8. Remove the 2 bolts and disconnect the engine wire protector labeled A.

      9. for RHD:

        Disconnect the wire harness from the wire harness clamp holder labeled C.

    2. RH Side:


      1. Disconnect the 7 connectors.

        A015AIHE01
        Text in Illustration
        *A w/ DPF *B w/o DPF
      2. Using a clip remover, detach the wire harness clamp.

      3. Remove the 3 bolts and disconnect the wire harness protector labeled A.

      4. Remove the bolt and wire harness bracket labeled B.

      5. Remove the screw grommet, nut and glow plug wire harness labeled C.

      6. A015CM3E01
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        for RHD:

        Disconnect the wire harness from the wire harness clamp holder.

      7. for RHD:

        Remove the bolt and wire harness clamp holder.

    3. Rear Side:


      1. A0157RZE01
        Text in Illustration
        *A w/ DPF
        *B w/o DPF

        Using a clip remover, detach the wire harness clamp.

      2. Remove the 2 bolts and 2 ground wires labeled C.

      3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

      4. w/ DPF:

        Disconnect the 3 connectors.

      5. w/o DPF:

        Disconnect the connector.

      6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.

  36. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Note


    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.

    • After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.


    1. A015D15

      Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

    2. Remove the bolt and No. 2 injection pipe clamp.

    3. Remove the union bolt and gasket.

    4. Remove the bolt, nut and No. 2 fuel pipe.

  37. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.


    1. w/ EGR System:


      1. A0157JU

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.

      3. Remove the No. 6 injection pipe.

    2. w/o EGR System:


      1. A0159AO

        Using a union nut wrench, loosen the No. 6 injection pipe ends.

      2. Remove the nut and No. 2 injection pipe clamp.

      3. Remove the bolt and No. 6 injection pipe.

  38. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)


    1. A01576L

      Disconnect the 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve.

  39. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)


    1. A015AL5

      Disconnect the 2 vacuum hoses.

    2. A0159QH

      Remove the 3 bolts and vacuum transmitting pipe.

  40. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)


    1. A015AO1

      Remove the 4 bolts and cylinder head cover silencer.

  41. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A01571T

      Disconnect the fuel hose.

    2. Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

  42. REMOVE INJECTION PIPE LH


    1. A015B4EE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. A015E5OE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  43. REMOVE NO. 2 FUEL PIPE (w/ DPF)


    1. A015CIM

      Remove the No. 4 fuel hose.

    2. Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.

  44. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. w/ DPF:


      1. Disconnect the fuel hose.

      2. A015E4L

        Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

    2. A0156LG

      w/o DPF:

      Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

  45. REMOVE COMMON RAIL ASSEMBLY LH


    1. A015BWVE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail.

      Note


      • Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

      • w/ DPF:

        Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

  46. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


    1. w/ DPF:


      1. A015D39

        Remove the bolt and No. 2 injection pipe clamp.

      2. Disconnect the fuel hose.

      3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.

    2. w/o DPF:


      1. A01588A

        Disconnect the 2 hoses from the fuel pipe.

      2. Remove the bolt and fuel filter to injection pump fuel pipe.

  47. DISCONNECT FUEL PUMP MOTOR WIRE


    1. A0159T3

      Remove the bolt and disconnect the connector from the fuel supply pump.

  48. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY


    1. A0156FM

      Using a union nut wrench, remove the No. 5 injection pipe.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.

  49. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)


    1. A015AD8

      Remove the 4 bolts and cylinder head cover silencer.

  50. REMOVE NO. 2 FUEL INJECTOR PROTECTOR (w/ DPF)


    1. A0156K1

      Detach the hose clamp.

    2. Remove the bolt and No. 2 fuel injector protector.

  51. REMOVE NO. 1 FUEL INJECTOR PROTECTOR (w/ DPF)


    1. A0156CK

      Remove the bolt and No. 1 fuel injector protector.

  52. REMOVE INJECTION PIPE RH


    1. A0155GHE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      w/ Intercooler:

      Remove the 2 nuts and 4 injection pipe clamps.

    2. A015B9WE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a union nut wrench, remove the 4 injection pipes.

      Note

      After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

  53. REMOVE COMMON RAIL ASSEMBLY RH


    1. A0157DVE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail.

      Note

      Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.

  54. REMOVE CONNECTING WIRE (w/ DPF)


    1. A0158N3

      Detach the 2 clamps and remove the connecting wire.

  55. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A0155NQ

      Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

  56. REMOVE NO. 2 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A015BOU

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Bolt
    2. Remove the 2 bolts and No. 2 nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  57. REMOVE NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A0156JO

      Remove the 4 injector hollow screws and 4 gaskets.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 No. 2 Check Valve
      A0158FK Union Bolt
    2. Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

    3. Remove the union bolt and No. 1 nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  58. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    A0155ZV
  59. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

    A01565Y
  60. REMOVE INTAKE PIPE


    1. A01580H

      w/ EGR System:

      Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

    2. A015CFP

      w/o EGR System:

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

  61. DISCONNECT NO. 2 ENGINE WIRE


    1. A0156MM

      Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

  62. REMOVE NO. 3 INTAKE MANIFOLD


    1. A0158GX

      Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

  63. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

    A0159XK
  64. REMOVE EGR PIPE INSULATOR (w/ EGR System)


    1. A015B26

      Remove the 2 bolts and EGR pipe insulator.

  65. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)


    1. A01584Z

      Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

    2. A015AI2

      Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

  66. REMOVE EGR COOLER INSULATOR (w/ EGR System)

    A015CP9
  67. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)


    1. A015AB8

      Disconnect the No. 1 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

      Note

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  68. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)


    1. A015AQI

      Disconnect the No. 2 fuel hose from the fuel cooler.

    2. Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

      Note

      After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

  69. DISCONNECT NO. 6 WATER BY-PASS HOSE (w/o DPF)

    A015A9V
  70. REMOVE FUEL COOLER ASSEMBLY (w/o DPF)


    1. A0159DJ

      Remove the 2 bolts and fuel cooler.

  71. REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)


    1. A0159VL

      Disconnect the 3 fuel tube connectors Click here.

    2. Detach the 3 clamps and remove the fuel tube.

  72. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A015B5OE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

  73. REMOVE FUEL HOSE BRACKET (w/ DPF)


    1. A015DU1

      Remove the bolt and fuel hose bracket.

  74. REMOVE NO. 1 FUEL PIPE CLAMP (w/ DPF)


    1. A0159I1E01
      Text in Illustration
      *a RH Side
      *b LH Side

      Remove the 2 bolts and 2 No. 1 fuel pipe clamps.

  75. REMOVE NO. 1 INTAKE MANIFOLD


    1. A0158DT

      Remove the 9 bolts, No. 1 intake manifold and gasket.

  76. REMOVE NO. 2 INTAKE MANIFOLD


    1. A0157X0

      Remove the 9 bolts, No. 2 intake manifold and gasket.

  77. REPLACE STUD BOLT

    Tech Tips

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A015CVME02

      For Intake Pipe:

      Using an E8 "TORX" wrench, replace the stud bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    2. A015C2JE02

      For No. 3 Intake Manifold:


      1. Using an E8 "TORX" wrench, replace the stud bolts labeled A.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
      2. Using an E6 "TORX" wrench, replace the stud bolts labeled B.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. Using an E6 "TORX" wrench, replace the stud bolt labeled C.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
  78. REPLACE RING PIN

    Tech Tips

    It is not necessary to remove a ring pin unless it is being replaced.


    1. A0157FYE02
      Text in Illustration
      *1 Protrusion height

      For No. 1 and No. 2 Intake Manifold:

      Replace the ring pins.

      Standard protrusion
      4.4 to 5.6 mm (0.173 to 0.222 in.)