Intake Manifold -- Removal |
| 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 |
Remove the 3 bolts, 2 nuts and cover.
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| 3. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR |
Remove the charge air cooler with intake air connector (Toyota Fortuner RM0000015B9002X.html).
| 4. REMOVE VACUUM SWITCHING VALVE BRACKET |
Disconnect the 2 connectors.
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Disconnect the vacuum hoses from the 3 locations.
Remove the 2 bolts and bracket.
| 5. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
Disconnect the throttle position sensor connector.
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Disconnect the throttle control motor connector.
Remove the 2 bolts, 2 nuts, throttle body and gasket.
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| 6. REMOVE THROTTLE BODY BRACKET |
Remove the 3 bolts and bracket.
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| 7. REMOVE INTAKE AIR CONNECTOR |
Remove the 2 nuts, bolt, air connector and gasket.
| 8. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY |
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Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.
| 9. REMOVE EGR VALVE ASSEMBLY |
Remove the EGR valve and gasket.
| 10. REMOVE MANIFOLD STAY |
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Remove the 2 bolts and stay.
| 11. REMOVE OIL DIPSTICK GUIDE |
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Remove the bolt and injection pipe clamp.
Remove the bolt and guide.
Remove the O-ring from the guide.
| 12. REMOVE INJECTION PIPE SUB-ASSEMBLY |
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- NOTICE:
- After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
Remove the 2 nuts and No. 3 injection pipe clamp.
Remove the bolt and No. 2 injection pipe clamp.
Using union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
Using union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
| 13. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Disconnect the 2 fuel hoses.
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Remove the check valve, 3 bolts, leakage pipe and gasket.
| 14. REMOVE INTAKE MANIFOLD |
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Disconnect the vacuum hose.
Disconnect the VSV connector.
Remove the 2 nuts, 4 bolts, intake manifold and gasket.