INTAKE MANIFOLD > INSTALLATION

for Preparation Click here



1. INSTALL INTAKE MANIFOLD


A099629E02

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

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

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



2. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


A098898E01

  1. Temporarily install the leakage pipe with the 3 bolts.

  1. Temporarily install a new gasket with the check valve.

  1. Fully tighten the 3 bolts and check valve.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf } for check valve
    13 N*m{ 133 kgf*cm , 10 ft.*lbf } for bolt

  1. Connect the 2 fuel hoses.



3. INSTALL INJECTION PIPE


G038585E02

NOTICE:
  1. When replacing the injector, also replace the injection pipe.
  2. Keep the joints of the injection pipe clean.

  1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

  1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

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

    HINT:
    If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.



    A098972E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



    A098893E01

  1. Temporarily install the No. 4 injection pipe with the union nuts.

  1. Install 2 new injection pipe clamps with the 2 bolts.

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

    NOTICE:
    1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
    2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.



    A098973E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



4. INSTALL OIL LEVEL GAUGE GUIDE


    A099624E01

  1. Install a new O-ring to the guide.

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

  1. Install the guide with the bolt.

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

  1. Install the injection pipe clamp with the bolt.

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



5. INSTALL MANIFOLD STAY


A099932E01

  1. Install the stay with the 2 bolts.

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

    HINT:
    The stay's indented area (labeled A) must face the manifold.



6. INSTALL EGR VALVE ASSEMBLY

  1. Install a new gasket and the EGR valve.



7. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


G037199E01

  1. Install 2 new gaskets and the pipe with the 2 nuts and 2 bolts.

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

    HINT:
    The gasket's claws should be on the pipe side.



8. INSTALL INTAKE AIR CONNECTOR


    A110300

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

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



9. INSTALL THROTTLE BODY BRACKET

  1. Install the bracket with the 3 bolts.

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



10. INSTALL DIESEL THROTTLE BODY ASSEMBLY


A111832

  1. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.

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



    A111790

  1. Connect the 2 connectors.



11. INSTALL VACUUM SWITCHING VALVE BRACKET


    A110298

  1. Install the bracket with the 2 bolts.

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

  1. Connect the vacuum hoses to the 3 locations.

  1. Connect the 2 connectors.



12. INSTALL CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

  1. Install the charge air cooler with intake air connector (Click here).



13. BLEED AIR FROM FUEL SYSTEM


14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


15. CHECK FOR FUEL LEAKS


A111544E01

CAUTION:
  1. During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
  2. 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.

  1. 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.

  1. Disconnect the return hose from the common rail.

  1. Start the engine and check for fuel leaks from the return pipe.
    If there is fuel leakage, replace the common rail.

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and push the intelligent tester main switch ON.

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

  1. 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.

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

    NOTICE:
    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.

  1. Reconnect the return hose to the common rail.



16. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    A110362

  1. Install the cover with the 3 bolts and 2 nuts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



17. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    CAUTION:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.