INTAKE MANIFOLD (w/o EGR System) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  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.

    Note

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

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DYO3

      Remove the 3 bolts, 2 nuts and cover.

  3. REMOVE INTERCOOLER ASSEMBLY

    Click here

  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01DZU2

      Disconnect the 2 connectors.

    2. A01E2KU

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

  5. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. A01DZTK

      Remove the 2 bolts and vacuum switching valve bracket.

  6. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. A01DZD1

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

  7. REMOVE INTAKE AIR CONNECTOR


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

  8. REMOVE MANIFOLD STAY

    A01E344E01

    1. Remove the 2 bolts and stay.

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    A01DWAOE01

    1. Remove the engine oil level dipstick.

    2. Remove the bolt and injection pipe clamp.

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

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

  10. REMOVE NO. 1, NO. 2 AND NO. 3 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.

  11. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E0ZRE01

      Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01E2XGE01

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  12. 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.

  13. REMOVE INTAKE MANIFOLD

    A01DXVHE02

    1. Disconnect the vacuum hose.

    2. Disconnect the VSV connector.

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