Intake Manifold Removal

Remove the 3 bolts and screw.

Loosen the clip and remove the front fender splash shield LH.

Remove the 3 bolts and 2 screws.

Loosen the clip and remove the front fender splash shield RH.

Remove the 10 bolts and No. 1 engine under cover.

Remove the 7 clips and upper radiator support seal.

Loosen the radiator drain cock plug.

Remove the radiator reservoir cap to drain the coolant in the radiator.

Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

Tighten the radiator drain cock plug by hand.

Tighten the oil filter bracket drain cock plug.

Torque:

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

Loosen the hose clamp.

Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

Detach the 4 clamps and remove the air cleaner cap.

Loosen the hose clamp and remove the No. 1 air cleaner hose.

w/ Viscous Heater:
Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

w/o Viscous Heater:
Disconnect the connector from the water temperature sensor.

Using a clip remover, detach the 3 wire harness clamps.

Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

Loosen the No. 1 air hose clamp.

Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

Remove the 3 nuts, bolt and No. 1 cool air inlet.

Remove the gasket from the air tube RH.

Loosen the No. 2 air hose clamp.

Remove the 3 nuts, bolt and No. 2 cool air inlet.

Remove the gasket from the air tube LH.

Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

Disconnect the ventilation hose from the cylinder head cover RH.

Remove the 2 bolts and No. 2 engine oil level dipstick guide.

Remove the O-ring from the No. 2 engine oil level dipstick guide.

Loosen the hose clamp.

Remove the air tube from the throttle body.

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket from the intake pipe.

Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

NOTICE:

1. Do not bend or damage the flexible hose tubes.
   
2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.
   

Remove the 2 clips.

Remove the bolt and clutch hose.

Loosen the hose clamp.

Remove the air tube from the throttle body.

Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

NOTICE:

1. Do not bend or damage the flexible hose tube.
   
2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.
   

Remove the 2 bolts and tube connector to flexible hose tube.

Disconnect the hose from the intake pipe.

Remove the No. 1 gas filter.

for Manual Transmission:

1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.
   

Remove the 2 bolts and No. 3 intercooler support bracket.

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket from the intake pipe.

Loosen the hose clamp and remove the No. 1 air hose.

Disconnect the wire harness from the clamp.

Remove the nut and ground wire.

Remove the bolt and disconnect the wire harness bracket.

Loosen the hose clamp and remove the bolt and No. 3 air tube.

Loosen the hose clamp and remove the No. 2 air hose.

Remove the bolt and disconnect the suction hose.

Loosen the hose clamp and remove the bolt and No. 4 air tube.

Disconnect the ventilation hose from the oil separator.

Loosen the hose clamp.

Remove the bolt and No. 2 air cleaner pipe.

Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

Loosen the hose clamp.

Remove the bolt and No. 1 air cleaner pipe.

w/ DPF:

w/o DPF:

Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

w/ EGR System:

1. Remove the 2 bolts and nut.
   
   

   
   
   
   
   

   Text in Illustration

   *A

   w/ DPF

   *B

   w/o DPF

2. w/ DPF:
   Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
   

3. w/o DPF:
   Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.
   

w/o EGR System:

1. Remove the 2 bolts and nut.
   

2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
   

LH Side:

1. Disconnect the 4 connectors.
   

2. Using a clip remover, detach the 3 wire harness clamps.
   





3. Disconnect the 2 connectors.
   

4. Using a clip remover, detach the 3 wire harness clamps.
   





5. Disconnect the 8 connectors.
   
   

   
   
   
   
   

   Text in Illustration

   *A

   w/ DPF

   *B

   w/o DPF

6. Remove the bolt and engine wire harness bracket labeled B.
   

7. Using a clip remover, detach the wire harness clamp labeled D.
   

8. Remove the 2 bolts and disconnect the engine wire protector labeled A.
   

9. for RHD:
   Disconnect the wire harness from the wire harness clamp holder labeled C.
   

RH Side:

1. Disconnect the 7 connectors.
   
   

   
   
   
   
   

   Text in Illustration

   *A

   w/ DPF

   *B

   w/o DPF

2. Using a clip remover, detach the wire harness clamp.
   

3. Remove the 3 bolts and disconnect the wire harness protector labeled A.
   

4. Remove the bolt and wire harness bracket labeled B.
   

5. Remove the screw grommet, nut and glow plug wire harness labeled C.
   





6. for RHD:
   Disconnect the wire harness from the wire harness clamp holder.
   

   Text in Illustration

   *A	w/ DPF
   *B	w/o DPF

7. for RHD:
   Remove the bolt and wire harness clamp holder.
   

Rear Side:

1. Using a clip remover, detach the wire harness clamp.
   

   Text in Illustration

   *A	w/ DPF
   *B	w/o DPF

2. Remove the 2 bolts and 2 ground wires labeled C.
   

3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.
   

4. w/ DPF:
   Disconnect the 3 connectors.
   

5. w/o DPF:
   Disconnect the connector.
   

6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.
   

Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

Remove the bolt and No. 2 injection pipe clamp.

Remove the union bolt and gasket.

Remove the bolt, nut and No. 2 fuel pipe.

w/ EGR System:

1. Using a union nut wrench, loosen the No. 6 injection pipe ends.
   

2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.
   

3. Remove the No. 6 injection pipe.
   

w/o EGR System:

1. Using a union nut wrench, loosen the No. 6 injection pipe ends.
   

2. Remove the nut and No. 2 injection pipe clamp.
   

3. Remove the bolt and No. 6 injection pipe.
   

Disconnect the 2 vacuum hoses.

Remove the bolt and vacuum switching valve.

Disconnect the 2 vacuum hoses.

Remove the 3 bolts and vacuum transmitting pipe.

Remove the 4 bolts and cylinder head cover silencer.

Disconnect the fuel hose.

Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.

Using a union nut wrench, remove the 4 injection pipes.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

Remove the No. 4 fuel hose.

Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.

w/ DPF:

1. Disconnect the fuel hose.
   





2. Remove the union bolt, gasket and No. 5 nozzle leakage pipe.
   

w/o DPF:
Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

Remove the 2 bolts and common rail.

NOTICE:

1. Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.
   
2. w/ DPF:
   Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.
   

w/ DPF:

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

2. Disconnect the fuel hose.
   

3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.
   

w/o DPF:

1. Disconnect the 2 hoses from the fuel pipe.
   

2. Remove the bolt and fuel filter to injection pump fuel pipe.
   

Remove the bolt and disconnect the connector from the fuel supply pump.

Using a union nut wrench, remove the No. 5 injection pipe.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.

Remove the 4 bolts and cylinder head cover silencer.

Detach the hose clamp.

Remove the bolt and No. 2 fuel injector protector.

Remove the bolt and No. 1 fuel injector protector.

w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.

Using a union nut wrench, remove the 4 injection pipes.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

Remove the 2 bolts and common rail.

NOTICE:

Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.

Detach the 2 clamps and remove the connecting wire.

Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

Remove the 4 injector hollow screws and 4 gaskets.

Text in Illustration

	Injector Hollow Screw
	Bolt

Remove the 2 bolts and No. 2 nozzle leakage pipe.

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 injector hollow screws and 4 gaskets.

Text in Illustration

	Injector Hollow Screw
	No. 2 Check Valve
	Union Bolt

Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

Remove the union bolt and No. 1 nozzle leakage pipe.

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

w/ EGR System:
Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

w/o EGR System:
Remove the 2 nuts, 4 bolts, intake pipe and gasket.

Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

Remove the 2 bolts and EGR pipe insulator.

Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

Disconnect the No. 1 fuel hose from the fuel cooler.

Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

NOTICE:

After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

Disconnect the No. 2 fuel hose from the fuel cooler.

Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

NOTICE:

After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

Remove the 2 bolts and fuel cooler.

Disconnect the 3 fuel tube connectors (Click here).

Detach the 3 clamps and remove the fuel tube.

Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

Remove the bolt and fuel hose bracket.

Remove the 2 bolts and 2 No. 1 fuel pipe clamps.

Remove the 9 bolts, No. 1 intake manifold and gasket.

Remove the 9 bolts, No. 2 intake manifold and gasket.

For Intake Pipe:
Using an E8 "TORX" wrench, replace the stud bolts.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

For No. 3 Intake Manifold:

1. Using an E8 "TORX" wrench, replace the stud bolts labeled A.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

2. Using an E6 "TORX" wrench, replace the stud bolts labeled B.
   

   Torque:

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

3. Using an E6 "TORX" wrench, replace the stud bolt labeled C.
   

   Torque:

   4.0 N*m{41 kgf*cm, 35 in.*lbf}

For No. 1 and No. 2 Intake Manifold:
Replace the ring pins.

Standard protrusion:

4.4 to 5.6 mm (0.173 to 0.222 in.)