INTAKE MANIFOLD REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body assembly Click here.

  2. DISCONNECT ENGINE WIRE

    A003BMP

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the grommet and nut, and disconnect the glow plug wire harness.

    4. Detach the 2 wire harness clamps.

    5. Remove the bolt and wire harness bracket.

    6. Remove the bolt and 3 nuts, and disconnect the engine wire.

  3. REMOVE EGR VALVE BRACKET


    1. A003E6M

      Disconnect the 2 connectors and detach the 2 wire harness clamps.

    2. A003E5Y

      Remove the 3 bolts and 2 EGR valve brackets.

  4. REMOVE NO. 7 WATER BY-PASS HOSE

    A003C0A

  5. DISCONNECT NO. 8 WATER BY-PASS HOSE

    A003C1D

  6. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A003BVE

      Disconnect the electric EGR control valve connector.

    2. A003CDBE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts and No. 2 EGR pipe.

    3. Remove the 2 gaskets.

  7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003AHE

      Remove the electric EGR control valve and gasket.

  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A003AJA

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  9. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A003DL2

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  10. REMOVE COMMON RAIL ASSEMBLY


    1. A003B5S

      Using pliers, grip the claws of the clip and slide the clip to disconnect the fuel hose.

    2. Remove the 2 bolts and common rail.

  11. REMOVE INTAKE MANIFOLD INSULATOR


    1. A003CC9

      Remove the intake manifold insulator from the intake manifold.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003E7T

      Disconnect the connector and detach the wire harness clamp from the engine oil level dipstick guide.

    3. Remove the 2 bolts and engine oil level dipstick guide.

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

  13. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A003BFA

      Disconnect the vacuum hose.

    2. Disconnect the sensor connector.

    3. Remove the bolt and sensor.

  14. REMOVE NO. 1 GAS FILTER


    1. A003BBJ

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  15. REMOVE GAS FILTER BRACKET


    1. A003AWW

      Remove the 2 bolts and gas filter bracket.

  16. REMOVE ENGINE COVER BRACKET


    1. A003EJ9

      Remove the bolt and engine cover bracket.

  17. REMOVE NO. 2 INTAKE MANIFOLD


    1. A003DE3

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  18. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. A003BTF

      Disconnect the No. 2 vacuum transmitting hose from the intake manifold.

  19. REMOVE INTAKE MANIFOLD


    1. A003DELE01
      Text in Illustration
      *1 Nut

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

    2. Remove the gasket from the cylinder head.

  20. REPLACE STUD BOLT

    Tech Tips

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


    1. A003AN0E01

      Replace the 2 stud bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }