INTAKE MANIFOLD (for DPF) 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 and fuel inlet pipe, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE INTAKE AIR CONNECTOR WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  3. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DW4L

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01E26N

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

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01DV6CE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Wiring Harness Clamp Bracket

      Detach the wire harness clamp.

    2. Remove the bolt and wiring harness clamp bracket.

  5. REMOVE NO. 2 FUEL PIPE


    1. A01DZ44

      Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.

    2. A01DWSC

      Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Supply Pump Hollow Screw
      A01E01H Fuel Check Valve
      A01DXHC Union Bolt

    3. Remove the fuel check valve, union bolt and 2 gaskets.

    4. Remove the 3 bolts and No. 2 fuel pipe.

  6. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DZSF

      Disconnect the 3 fuel hoses.

      Text in Illustration
      A01DZ8Z Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  7. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01E159

      Remove the 2 bolts.

      Text in Illustration
      A01DZ8Z Union Bolt

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

  8. REMOVE GLOW CONNECTOR BRACKET

    A01E2YG

    1. Disconnect the No. 1 glow plug connector and detach the clamp.

    2. A01E2RF

      Remove the bolt and glow connector bracket.

  9. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. A01DVFY

      Remove the bolt and No. 3 intercooler support bracket.

  10. REMOVE NO. 2 MANIFOLD STAY


    1. A01DW69

      Remove the bolt and No. 2 manifold stay.

  11. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A01DVUT

      Remove the 4 screw grommets.

    2. A01DYFA

      Remove the 4 nuts and No. 1 glow plug connector.

  12. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    A01DVZP

  13. REMOVE INTAKE MANIFOLD INSULATOR

    A01DYBF

  14. REMOVE INTAKE MANIFOLD


    1. A01DYZ9

      Disconnect the vacuum hose from the intake manifold.

    2. A01DXXD

      Detach the sensor wire connector clamp from the intake manifold.

    3. A01E0FJ

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