INTAKE MANIFOLD INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. A0099ANE02
      Text in Illustration
      *a Protrusion
      *b Upward

      Install a new gasket to the cylinder head with the protrusion facing upward.

    2. A0099VAE01
      Text in Illustration
      *1 Nut

      Install the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.

      Torque:
      24 N*m  { 240 kgf*cm, 17 ft.*lbf }

    3. Install the wire harness bracket with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

  2. INSTALL INJECTION PIPE


    1. Install the 2 lower clamps to the intake manifold.

    2. A009AIT

      Using a 17 mm union nut wrench, install the 4 injection pipes.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Secure the injection pipes by installing the 2 upper pipe clamps and 2 nuts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install a new gasket and the diesel throttle body.

    2. Connect the throttle control motor connector.

    3. Install the bracket with the 2 bolts.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

    4. Connect the throttle open switch connector.

  4. INSTALL INTAKE FLANGE


    1. Install a new gasket and the intake flange with the 3 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the manifold absolute pressure sensor connector.

    3. Install the heater hose bracket with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    4. Connect the PCV hose.

  5. INSTALL INTAKE PIPE


    1. Install the intake pipe with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Tighten the intake pipe clamp.

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

  6. BLEED INJECTION PIPE


    1. Move the hand pump on the upper part of the fuel filter up and down and fill the injection pump and fuel system with fuel.

    2. Loosen one of the union nuts (on the nozzle side).

    3. Crank the engine until fuel comes out from the union nut connection (on the nozzle side).

    4. Tighten the union nut.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    5. Perform the procedures above for each injection pipe.

  7. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

      Tech Tips

      When checking for fuel leaks, make sure that there is pressure in the fuel line.