GSIC - Global Service Information Center

# 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

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

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

1. Disconnect the 2 connectors.

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

6. REMOVE THROTTLE BODY BRACKET

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

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

1. Remove the 2 bolts and stay.

11. REMOVE OIL LEVEL GAUGE GUIDE

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

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

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

   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

1. Disconnect the 2 fuel hoses.

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

14. REMOVE INTAKE MANIFOLD

1. Disconnect the vacuum hose.

1. Disconnect the VSV connector.

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