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

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  2. DISCONNECT ENGINE WIRE

    A01IRBA

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the screw 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. A01IPQ0

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

    2. A01IPI2

      Remove the 3 bolts and 2 EGR valve brackets.

  4. REMOVE NO. 7 WATER BY-PASS HOSE

    A01IUFE

  5. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. A01INDM

      Slide the clamp and disconnect the No. 8 water by-pass hose from the electric EGR control valve assembly.

  6. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IOQA

      Disconnect the electric EGR control valve connector.

    2. A01IPRKE01
      Text in Illustration
      *1 Nut

      Remove the 3 bolts, 2 nuts, No. 2 EGR pipe sub-assembly and 2 gaskets.

  7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IQP8

      Remove the electric EGR control valve assembly 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. A01ITN1

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

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

  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. A01IO2G

      Remove the 2 bolts and 4 No. 2 injection pipe clamps.

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

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

    4. Remove the 4 injection pipes.

  10. REMOVE COMMON RAIL ASSEMBLY


    1. A01IUFT

      Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 4 fuel hose from the common rail assembly.

    2. Remove the 2 bolts and common rail assembly.

  11. REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IQK4

      Remove the intake manifold insulator from the intake manifold.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IMYE

      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. A01IQ0K

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  14. REMOVE NO. 1 GAS FILTER


    1. A01IQMA

      Disconnect the vacuum hose.

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

  15. REMOVE GAS FILTER BRACKET


    1. A01ITRH

      Remove the 2 bolts and gas filter bracket.

  16. REMOVE ENGINE COVER BRACKET


    1. A01INXS

      Remove the bolt and engine cover bracket.

  17. REMOVE NO. 2 INTAKE MANIFOLD


    1. A01IPPN

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

  18. DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. A01IPLK

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

  19. REMOVE INTAKE MANIFOLD


    1. A01IOHHE01
      Text in Illustration
      *1 Nut

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

  20. REPLACE STUD BOLT

    Tech Tips

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


    1. A01IQH0E01

      Replace the 2 stud bolts.

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