INTAKE MANIFOLD > REMOVAL

for Preparation Click here



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.



2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    A110362

  1. Remove the 3 bolts, 2 nuts and cover.



3. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

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



4. REMOVE VACUUM SWITCHING VALVE BRACKET


    A110298

  1. Disconnect the 2 connectors.

  1. Disconnect the vacuum hoses from the 3 locations.

  1. Remove the 2 bolts and bracket.



5. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    A111790

  1. Disconnect the 2 connectors.



    A111832

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



6. REMOVE THROTTLE BODY BRACKET


    A110300

  1. Remove the 3 bolts and bracket.



7. REMOVE INTAKE AIR CONNECTOR

  1. Remove the 2 nuts, bolt, air connector and bracket.



8. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


A099621E01

  1. Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.



9. REMOVE EGR VALVE ASSEMBLY

  1. Remove the EGR valve and gasket.



10. REMOVE MANIFOLD STAY


A099622E01

  1. Remove the 2 bolts and stay.



11. REMOVE OIL LEVEL GAUGE GUIDE


A099624E01

  1. Remove the bolt and injection pipe clamp.

  1. Remove the bolt and guide.

  1. Remove the O-ring from the guide.



12. REMOVE INJECTION PIPE SUB-ASSEMBLY


A098967E02

NOTICE:
  1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
  2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  1. Remove the 2 nuts and No. 3 injection pipe clamp.

  1. Remove the bolt and No. 2 injection pipe clamp.



  1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

    SST
    09023-12701  



      A098893E01

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



      2. A098968E01

    2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
      09023-12701  



13. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


A098898E01

  1. Disconnect the 2 fuel hoses.

  1. Remove the check valve, 3 bolts, leakage pipe and gasket.



14. REMOVE INTAKE MANIFOLD


A099626E01

  1. Disconnect the vacuum hose.

  1. Disconnect the VSV connector.

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