INTAKE MANIFOLD INSTALLATION

CAUTION / NOTICE / HINT

Note:

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

  • When replacing the supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE

  1. INSTALL STUD BOLT

    Tip:

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. A197560C02

      *a

      40 mm (1.57 in.)

      *b

      16 mm (0.630 in.)

      Install the 2 stud bolts to the intake manifold.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  2. INSTALL INTAKE MANIFOLD

    1. A294420E01

      Install a new gasket to the cylinder head.

      Tip:

      Install the gasket with the part (A) facing the right side of the vehicle as shown in the illustration.

    2. A294421C01
      V100135

      Bolt
      V100136

      Nut

      Install the intake manifold with the 7 bolts and 2 nuts.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

      Bolt Length

      Item

      Length

      Bolt A

      90 mm (3.54 in.)

      Bolt B

      25 mm (0.984 in.)

  3. CONNECT NO. 2 VACUUM TRANSMITTING HOSE

    1. Connect the No. 2 vacuum transmitting hose to the intake manifold and slide the clip to secure it.

  4. CONNECT NO. 2 INTAKE MANIFOLD

    1. Install a new gasket and No. 2 intake manifold with the bolt and 2 nuts.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

  5. INSTALL ENGINE COVER BRACKET

    1. Install the engine cover bracket with the bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  6. INSTALL GAS FILTER BRACKET

    1. Install the gas filter bracket with the 2 bolts.

      8.8 N*m

      90 kgf*cm

      78 in.*lbf

  7. INSTALL NO. 1 GAS FILTER

    1. A197554C01

      *1

      Protrusion

      *2

      Groove

      Install the No. 1 gas filter to the gas filter bracket.

      Note:

      Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.

    2. Connect the vacuum hose.

  8. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR (DIESEL TURBO PRESSURE SENSOR)

    Click here

  9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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

    2. Install the engine oil level dipstick guide with the 2 bolts.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

    3. Connect the connector and then the wire harness clamp to the engine oil level dipstick guide.

    4. Install the engine oil level dipstick.

  10. INSTALL INTAKE MANIFOLD INSULATOR

    1. Install the intake manifold insulator to the intake manifold.

  11. INSTALL COMMON RAIL ASSEMBLY

    Click here

  12. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Click hereClick here

  13. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  14. INSTALL EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    Click here

  15. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  16. CONNECT NO. 8 WATER BY-PASS HOSE

    Click here

  17. CONNECT NO. 7 WATER BY-PASS HOSE

    Click here

  18. INSTALL EGR VALVE BRACKET

    Click here

  19. CONNECT ENGINE WIRE

    Click hereClick here

  20. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  21. BLEED AIR FROM FUEL SYSTEM

    Click here

  22. INSPECT FOR FUEL LEAK

    Click here