INTAKE MANIFOLD INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. A01E0KME03
      Text in Illustration
      *1 No. 1 Manifold Insulator

      Temporarily install a new gasket and the intake manifold with the 4 bolts and 2 nuts.

      w/ Intercooler:

      Note


      • When installing the intake manifold, make sure that the No. 1 manifold insulator is not pinched.


      • Make sure that the swirl control valve actuator is not damaged by surrounding parts.

    2. A01E11HE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler

      Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    3. w/ Intercooler:

      Connect the vacuum hose and connector to the vacuum switching valve.

  2. INSTALL NO. 2 MANIFOLD STAY (w/ Intercooler)


    1. Install the No. 2 manifold stay with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  3. INSTALL INTAKE MANIFOLD INSULATOR (w/ Intercooler)


    1. A01DX3EE03
      Text in Illustration
      *1 Intake Manifold
      *2 Insulator
      *3 Common Rail

      Install the intake manifold insulator with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  4. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET (w/ Intercooler)


    1. A01DWTK

      Install the No. 3 intercooler support bracket with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  5. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


  6. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY


  7. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY


  8. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ Intercooler)


    1. Install a new gasket and the electric EGR control valve.

    2. Connect the EGR valve position sensor connector.

  9. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. w/ Intercooler:


      1. Temporarily install the No. 1 EGR pipe and 2 new gaskets to the cylinder head and EGR valve adapter with the 2 nuts and 2 bolts.

        Note

        Make sure the claws of the gasket face the No. 1 EGR pipe as shown in the illustration.

      2. Tighten the 2 nuts labeled A.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      3. Tighten the 2 bolts labeled B.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
        A01DY4LE01
        Text in Illustration
        *1 New Gasket *2 Claw
    2. A01DY8CE01
      Text in Illustration
      *1 Claw

      w/o Intercooler:

      Install 2 new gaskets and the No. 1 EGR pipe with the 2 nuts and 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Tech Tips

      Make sure the claws of the gasket face the No. 1 EGR pipe.

  10. TIGHTEN INTAKE AIR CONNECTOR (w/ Intercooler)


    1. Tighten the 3 nuts labeled A in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Tighten the 3 bolts labeled B in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

      A01DZ5LE02
      Text in Illustration
      *a Front Side of Vehicle - -

  11. INSTALL INTAKE AIR CONNECTOR (w/o Intercooler)


    1. Install a new gasket and the intake air connector with the 2 nuts and bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  12. INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET (w/o Intercooler)


    1. w/ Intercooler:


      1. A01E1G1E01

        Temporarily install the No. 2 intake air connector bracket with the 3 bolts.

      2. Tighten the bolt labeled A.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      3. Tighten the 2 bolts labeled B.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. w/o Intercooler:

      Install the No. 2 intake air connector bracket with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  13. INSTALL VACUUM SWITCHING VALVE BRACKET (w/o Intercooler)


    1. w/o EGR System:


      1. Install the vacuum switching valve bracket with the 2 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. w/ EGR System without EGR Cooler:


      1. Install the vacuum switching valve bracket with the 2 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      2. Connect the vacuum hoses to the 2 locations and 2 connectors.

  14. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ Intercooler)

    Click here

  15. INSTALL EGR COOLER

    Click here

  16. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Apply a small amount of clean engine oil to the O-ring.

    3. Install the engine oil level dipstick guide with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Install the injection pipe clamp with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  17. INSTALL MANIFOLD STAY (w/o Intercooler)


    1. A01DWLBE01

      Install the manifold stay with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Tech Tips

      The manifold stay indented area (labeled A) must face the manifold.

  18. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ Intercooler)


    1. Install the manifold stay with vacuum switching valve with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the 3 vacuum transmitting hoses and 2 vacuum switching valve connectors.

      Note

      Be sure to securely connect the vacuum transmitting hose.

  19. INSTALL DIESEL THROTTLE BODY ASSEMBLY


  20. ADD ENGINE COOLANT (w/ Intercooler)


  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  22. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01DYT1E05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  23. INSPECT FOR FUEL LEAK

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

    2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

    3. Disconnect the return hose from the common rail.

    4. Start the engine and check for fuel leaks from the return pipe.

      If there is fuel leakage, replace the common rail.

    5. Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch on.

    7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

    8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

      If there is fuel leakage, repair or replace parts as necessary.

    10. Reconnect the return hose to the common rail.

  24. INSPECT FOR COOLANT LEAK (w/ Intercooler)

  25. INSPECT FOR OIL LEAK

  26. INSPECT FOR ENGINE OIL LEVEL