INTAKE MANIFOLD REMOVAL


  1. REMOVE RADIATOR ASSEMBLY

    Click here

  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  3. REMOVE ENGINE COVER

    A01IRTM

  4. DISCONNECT ENGINE WIRE


    1. A01IO8C

      Detach the 2 clamps and disconnect the glow plug controller assembly harness connector.

    2. A01IOC2

      Detach the 5 clamps and disconnect the fuel quantity control valve connector.

    3. A01ISXM

      Disconnect the fuel pressure sensor connector.

    4. Disconnect the engine coolant temperature sensor connector.

    5. Disconnect the generator assembly connector.

    6. Disconnect the camshaft position sensor connector.

    7. Disconnect the turbo pressure sensor assembly connector.

    8. Disconnect the 2 glow plug controller assembly connectors.

    9. Detach the 2 clamps.

    10. Using a T25 "TORX" socket wrench, remove the screw and disconnect the engine wire.

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IRBY

      Detach the clamp and disconnect the fuel feed pipe sub-assembly from the engine oil level dipstick guide.

    3. Using a T25 "TORX" socket wrench, remove the bolt and engine oil level dipstick guide.

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

  6. DISCONNECT NO. 2 VACUUM HOSE ASSEMBLY


    1. A01IR4WE01
      Text in Illustration
      *1 No. 1 Vacuum Pipe

      Disconnect the No. 2 vacuum hose assembly from the No. 1 vacuum pipe.


      1. Check that there is no damage or foreign matter on the part of the No. 1 vacuum pipe that contacts the No. 2 vacuum hose assembly connector.

      2. A01ISEDE01
        Text in Illustration
        *1 Retainer
        A01ISM9 Pinch
        A01ISER Pull Out

        If the No. 2 vacuum hose assembly connector and No. 1 vacuum pipe are stuck together, hold the No. 1 vacuum pipe by hand and push and pull on the No. 2 vacuum hose assembly connector.

        Note


        • Check for any dirt and foreign matter contamination in the No. 1 vacuum pipe and around the No. 2 vacuum hose assembly connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

        • Do not use any tools to separate the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector.

        • Check for any dirt and foreign matter on the No. 1 vacuum pipe seal surface. Clean if necessary.

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the No. 2 vacuum hose assembly.

        • If the No. 1 vacuum pipe and No. 2 vacuum hose assembly connector are stuck together, pinch the No. 2 vacuum hose assembly connector between your fingers and turn it carefully to free it. Then disconnect the No. 2 vacuum hose assembly.

      3. Check for dirt or mud on the No. 1 vacuum pipe seal surface of the disconnected No. 1 vacuum pipe. Clean if necessary.

      4. To protect the disconnected No. 1 vacuum pipe and No. 2 vacuum hose assembly connector from damage and contamination, cover them with a plastic bag and tape.

  7. REMOVE NO. 1 VACUUM PIPE


    1. A01IPF5

      Disconnect the vacuum hose.

    2. Using an E7 "TORX" socket wrench, remove the bolt and No. 1 vacuum pipe from the cylinder block sub-assembly.

    3. Remove the O-ring from the No. 1 vacuum pipe.

  8. REMOVE INTAKE MANIFOLD


    1. A01IT6GE01

      Remove the bolt labeled B and loosen the 6 bolts labeled A in the order shown in the illustration, and then remove the intake manifold.

      Text in Illustration
      A01ISM9 Bolt A
      A01ISER Bolt B

      Tech Tips

      The bolts labeled A in the illustration cannot be removed from the intake manifold.

    2. A01IOAX

      Remove the 4 gaskets from the intake manifold.

    3. Remove the gasket from the No. 2 EGR pipe sub-assembly.

  9. REMOVE TURBO PRESSURE SENSOR ASSEMBLY


    1. A01IQ2H

      Disconnect the turbo pressure sensor connector.

    2. Using a T27 "TORX" socket wrench, remove the bolt and turbo pressure sensor assembly.

  10. REMOVE GLOW PLUG CONTROLLER ASSEMBLY

    A01IOEB

    1. Disconnect the 2 connectors.

    2. Using a T25 "TORX" socket wrench, remove the bolt and glow plug controller assembly.

  11. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IQZO

      Remove the No. 2 EGR pipe sub-assembly from the intake manifold.

    2. A01IOEVE01
      Text in Illustration
      *1 O-Ring

      Remove the O-ring from the No. 2 EGR pipe sub-assembly.