GSIC - Global Service Information Center

# INTAKE MANIFOLD > INSTALLATION

## for Preparation Click here

1. INSTALL INTAKE MANIFOLD

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

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

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.

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.).

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.

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

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

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

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

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

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 }

1. Connect the 2 connectors.

11. INSTALL VACUUM SWITCHING VALVE BRACKET

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

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

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.