Intake Manifold Removal and Installation

1)Remove engine assembly.  

2)Remove generator. 

3)Remove timing belt.  

4)Remove inlet throttle valve.  

5)Remove engine oil vapor separator.  

6)Remove engine harness.

7)Remove engine oil vapor pipe bolts (1).

8)Remove EGR pipe (1), gasket and O-ring.

9)Disconnect water hose (1) from intake manifold.

10)Disconnect fuel return hose (2) from fuel damper (3).

11)Remove fuel damper from intake manifold.

12)Remove fuel high pressure pipe between high pressure pump and common rail.  

13)Remove high pressure pump mounting with high pressure pump.  

14)Remove intake manifold nuts in numerical order (“1” – “9”) evenly and gradually.

15)Remove intake manifold (1) and gasket.

1)Install intake manifold (1) with new gasket.

2)Tighten intake manifold nuts in numerical order (“1” – “9”) evenly and gradually by repeating tightening procedure two or three times until specified torque is obtained.

3)Install high pressure pump mounting with high pressure pump.  

4)Install high pressure pipe.  

5)Install fuel damper (3) to intake manifold.

6)Connect fuel return hose (2) and water hose (1).

7)Install EGR pipe (1) with new gasket and new O-ring.

8)Install engine oil vapor pipe bolts (1).

9)Install engine harness.

10)Install engine oil vapor separator.  

11)Install inlet throttle valve.  

12)Install timing belt.  

13)Install generator.  

14)Install engine assembly.