REMOVAL AND INSTALLATION <4D5>


Pre-removal Operation
  • Vacuum Hose Removal (Refer to GROUP 11D - Solenoid Valve and Vacuum Hose ).
  • Throttle Body Removal (Refer to GROUP 13B - Throttle Body ) <Vehicles without Intercooler>.
  • Throttle Body Removal (Refer to GROUP 13B - Throttle Body ) <Vehicles with Intercooler>.
  • EGR Valve and EGR Pipe Removal (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).

 Post-installation Operation
  • EGR Valve and EGR Pipe Installation (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Throttle Body Installation (Refer to GROUP 13B - Throttle Body ) <Vehicles without Intercooler>.
  • Throttle Body Installation (Refer to GROUP 13B - Throttle Body ) <Vehicles with Intercooler>.
  • Vacuum Hose Installation (Refer to GROUP 11D - Solenoid Valve and Vacuum Hose ).

<Vehicles without Intercooler>

Removal steps


·
 Control wiring harness connection


1.
 Intake air temperature sensor No.2


2.
 Gasket


3.
 Vacuum pipe B


4.
 Vacuum pipe A


5.
 Engine cover stay A


6.
 Fuel inlet pipe mounting bolt


7.
 Inlet manifold stay


·
 Throttle solenoid valve (Refer to GROUP 11D - Solenoid Valve and Vacuum Hose ).


·
 Fuel injection pipe No.3, 4 clamp mounting bolt (Refer to GROUP 13B - Common Rail and Supply Pump ).

>>C<<
 8.
 Inlet manifold


9.
 Helical gasket

>>B<<
 10.
 Tangential gasket

>>A<<
 11.
 Stud


12.
 Engine hanger

<Vehicles with Intercooler>

Removal steps


·
 Control wiring harness connection


1.
 Intake air temperature sensor No.2


2.
 Gasket


3.
 Vacuum pipe B


4.
 Vacuum pipe A


5.
 Engine cover stay A


6.
 Fuel inlet pipe mounting bolt


7.
 Inlet manifold stay


·
 Fuel injection pipe No.3, 4 clamp mounting bolt (Refer to GROUP 13B - Common Rail and Supply Pump ).

>>C<<
 8.
 Inlet manifold


9.
 Helical gasket

>>B<<
 10.
 Tangential gasket


11.
 Engine hanger

INSTALLATION SERVICE POINTS

>>A<< STUD INSTALLATION
The stud should protrude 58 to 60 mm from the end of the inlet manifold.

>>B<< TANGENTIAL GASKET INSTALLATION

Position the projection as shown in the illustration.

>>C<< INLET MANIFOLD INSTALLATION

1.As shown in the illustration, temporarily tighten to 6.5 ± 1.5 N·m the bolts located at side A.
2.As shown in the illustration, tighten the bolts and nuts located at side B to the specified torque.
Tightening torque:
    Bolt: 24 ± 3 N·m
    Nut: 20 ± 2 N·m
3.As shown in the illustration, tighten the bolts located at side A to the specified torque.
Tightening torque: 24 ± 3 N·m