INTAKE MANIFOLD REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. DRAIN ENGINE COOLANT (w/ Intercooler)


  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY


  5. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ Intercooler)


    1. A01DYJJ

      Disconnect the vacuum switching valve connector.

    2. A01DZ46

      Disconnect the 3 vacuum transmitting hoses.

    3. A01DWYI

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  6. REMOVE MANIFOLD STAY (w/o Intercooler)


    1. A01E344E01

      Remove the 2 bolts and manifold stay.

  7. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01DV94E01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler

      Remove the bolt and injection pipe clamp.

    2. Remove the bolt and engine oil level dipstick guide.

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

  8. REMOVE EGR COOLER

    Click here

  9. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)

    Click here

  10. REMOVE VACUUM SWITCHING VALVE BRACKET (w/o Intercooler)


    1. w/ EGR System without EGR Cooler:


      1. A01DXD3

        Remove the 2 connectors from the E-VRV and EGR valve.

      2. Disconnect the vacuum hoses from the 2 locations.

      3. Remove the 2 bolts and vacuum switching valve bracket.

    2. w/o EGR System:


      1. A01DZTK

        Remove the 2 bolts and vacuum switching valve bracket.

  11. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/o Intercooler)


    1. A01DVDTE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
      *1 No. 2 Intake Air Connector Bracket
      *2 Intake Air Connector

      Remove the 3 bolts and No. 2 intake air connector bracket.

  12. REMOVE INTAKE AIR CONNECTOR (w/o Intercooler)


    1. Remove the 2 nuts, bolt, intake air connector and gasket.

  13. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/o Intercooler)


    1. A01DWYQ

      w/ Intercooler:

      Remove the 2 bolts, No. 1 EGR pipe and gasket from the EGR valve adapter.

    2. A01DY8CE01
      Text in Illustration
      *1 Gasket

      w/o Intercooler:

      Remove the 2 bolts, 2 nuts, No. 1 EGR pipe and 2 gaskets.

  14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o Intercooler)


    1. A01E03L

      w/ Intercooler:

      Remove the 2 bolts, electric EGR control valve and gasket from the EGR valve adapter.

    2. w/o Intercooler:


      1. Disconnect the EGR valve position sensor connector.

      2. Remove the electric EGR control valve and gasket.

  15. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY


  16. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


  17. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


  18. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET (w/ Intercooler)


    1. A01DWTK

      Remove the bolt and support bracket.

  19. REMOVE INTAKE MANIFOLD INSULATOR (w/ Intercooler)


    1. A01E05M

      Remove the 2 bolts and insulator from the manifold.

  20. REMOVE NO. 2 MANIFOLD STAY (w/ Intercooler)


    1. Remove the bolt and No. 2 manifold stay.

  21. REMOVE INTAKE MANIFOLD


    1. A01DY7XE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler

      w/ Intercooler:

      Disconnect the vacuum hose and vacuum switching valve connector.

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