MANIFOLD-INTAKE
REMOVAL
1. Remove the engine cover.
2. Disconnect the battery. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/CABLES - REMOVAL)
3. Remove the silencer.
4. Drain the coolant. (Refer to 7 - COOLING - STANDARD PROCEDURE)
5. Remove the upper radiator hose.
6. Disconnect the generator connector (4).
7. Remove the battery feed wire from the generator (3).
8. Remove the generator bolts (1), and remove the generator.
9. Remove the generator brace (1).
10. Remove the high pressure fuel line from the fuel rail.
11. Remove the fuel lines (3).
12. Remove the fuel rail (6)..
13. Disconnect the glow plug connectors.
14. Disconnect the fuel return lines.
15. Remove the fuel return line junction block.
16. Remove the heater hoses from the engine block.
17. Remove the EGR cooler.
18. Remove the thermostat housing.
19. Remove the coolant hose from the water pump.
20. Disconnect the coolant temperature sensor.
21. Remove the idler pulley support bracket (1).
22. Remove the fuel filter lines.
23. Remove the fuel filter.
24. Remove the intake manifold.
25. Remove the intake manifold gasket (2).
INSTALLATION
1. Clean and inspect the gasket surface of the intake manifold.
2. Clean and inspect the gasket surface of the cylinder head.
3. Install the intake manifold gasket (2).
4. Install the intake manifold.
5. Using the torque sequence in the illustration, torque the intake manifold bolts to 25 nm (18.4 ft. lbs.).
6. Install the idler pulley support bracket (1).
7. Install the fuel filter.
8. Install the fuel filter lines.
9. Connect the glow plug connectors.
10. Install the EGR cooler.
11. Install the fuel return line junction block.
12. Connect the fuel return lines.
13. Install the heater hoses.
14. Install the coolant hose to the water pump.
15. Install the cooling lines to the water pump outlet.
16. Connect the coolant temperature sensor.
17. Install the thermostat housing.
18. Install the coolant lines to the thermostat housing.
19. Install the fuel rail (6).
20. Install the fuel lines (3).
21. Install the generator brace (1).
22. Install the high pressure fuel line (2) to the fuel rail.
23. Install the generator.
24. Connect the generator connector (4).
25. Install the battery feed wire to the generator (3).
26. Remove the upper radiator hose.
27. Fill the coolant. (Refer to 7 - COOLING - STANDARD PROCEDURE)
28. Install the silencer.
29. Connect the battery. (Refer to 7 - COOLING - STANDARD PROCEDURE)
30. Install the engine cover.