INTAKE MANIFOLD (w/ EGR System without EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DYO3

      Remove the 3 bolts, 2 nuts and cover.

  3. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    1. Remove the charge air cooler with intake air connector Click here.

  4. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. A01DWGJ

      Disconnect the 2 connectors.

    2. Disconnect the vacuum hoses from the 3 locations.

    3. Remove the 2 bolts and bracket.

  5. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01DZU2

      Disconnect the 2 connectors.

    2. A01E2KU

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

  6. REMOVE THROTTLE BODY BRACKET


    1. A01E1XR

      Remove the 3 bolts and bracket.

  7. REMOVE INTAKE AIR CONNECTOR


    1. Remove the 2 nuts, bolt, air connector and bracket.

  8. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    A01DYONE01

    1. Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.

  9. REMOVE EGR VALVE ASSEMBLY


    1. Remove the EGR valve and gasket.

  10. REMOVE MANIFOLD STAY

    A01E344E01

    1. Remove the 2 bolts and stay.

  11. REMOVE OIL LEVEL GAUGE GUIDE

    A01DWAOE01

    1. Remove the bolt and injection pipe clamp.

    2. Remove the bolt and guide.

    3. Remove the O-ring from the guide.

  12. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

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


    1. A01DXPXE01

      Remove the bolt and No. 2 injection pipe clamp.

    2. Remove the 2 nuts and No. 3 injection pipe clamp.

    3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  13. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DWIZE05

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

  14. REMOVE INTAKE MANIFOLD

    A01DXVHE01

    1. Disconnect the vacuum hose.

    2. Disconnect the VSV connector.

    3. Remove the 2 nuts, 4 bolts, intake manifold and gasket.