Intake manifold
1. Intake manifold gasket
2. intake manifold
3. O-ring of the exhaust gas recirculation pipe assembly (EGR)
4. EGR pipe assembly (EGR)
5. Gasket assembly of the branch pipe of the exhaust gas recirculation system (EGR)
6. Control valve for the creation of vortex flows in the air-fuel mixture
7. Air intake control valve
Removal and installation
1. Remove the cover (A) engine.
2. Remove protection (A) sump.
3. Remove the drain plug (A) radiator and drain the engine coolant. Remove the radiator cap to speed up draining.
4. Remove the air filter assembly.
(1) Remove the duct (A).
(2) Disconnect connector (IN) mass air flow sensor (AFS).
(3) Disconnect the hose (WITH) breather.
(4) Disconnect the hose (D) air intake and remove the air filter (E) assembled.
Note: Tightening torque:
- Clamps: 2.9-4.9 Nm.
- Bolts: 7.8-9.8 Nm.
5. Disconnect the terminals (A) battery and remove the battery (IN).
Note:
Torque:
(-) output: 4.0-6.0 Nm. (+) output: 7.8 - 11.8 Nm. Bracket bolt: 9.8 - 11.8 Nm.
6. Remove the shelf (A) battery.
Note: Tightening torque: 9.8 - 11.8 Nm.
7. Disconnect connector (A) intake air temperature sensor and disconnect the intake (IN) and graduation (WITH) pipe and intercooler hose.
Note:
Tightening torque: Clamps: 4.9 - 6.9 Nm. Bolt: 9.8 - 11.8 Nm.
Standard power
Disconnect connector (A) boost pressure sensor (BPS) and disconnect the intake (IN) and graduation (WITH) pipe and intercooler hose.
Reduced power
8. Remove the top (A) and bottom (IN) radiator hoses.
9. Disconnect the engine harness connectors and remove the harness clamps from the cylinder head cover and intake manifold.
(1) Disconnect connector (A) pressure change sensor. (With particulate filter).
(2) Disconnect connector (IN) exhaust gas temperature sensor. (With particulate filter).
(3) Disconnect connector (WITH) oxygen sensor.
(4) Disconnect connector (A) camshaft position sensor (CMPS).
(5) Disconnect connector (IN) fuel rail pressure sensor.
(6) Disconnect connector (WITH) glow plugs.
(7) Disconnect connector (D) fuel pressure regulator.
(8) Disconnect connector (E) boost pressure sensor (BPS). (Only for engines of standard power).
(9) Disconnect connector (F) oil pressure sensor.
(10) Disconnect connector (G) crankshaft position sensor (CKPS).
(11) Disconnect connector (H) exhaust gas cooling valve (EGR).
(12) Disconnect connector (I) fuel temperature sensor.
(13) Disconnect connector (J) fuel rail pressure regulator.
(14) Disconnect the injector connectors (TO).
(15) Disconnect connector (L) air control valve.
Standard power
Reduced power
(16) Disconnect connector (A) control drive for the creation of vortex flows in the air-fuel mixture.
(17) Disconnect connector (IN) coolant temperature sensor (ECTS).
(18) Disconnect connector (WITH) variable geometry turbocharger electric drive (E-VGT).
(19) Disconnect connector (D) exhaust gas recirculation drive (EGR).
(20) Disconnect connector (A) generator and cable (IN).
(21) Disconnect connector (WITH) starter and cable (D).
(22) Disconnect connector (E) air compressor switch.
10. Remove protection (A) wiring harness.
11. Disconnect the fuel hose (A), branch pipes (IN) high pressure and vacuum hose (WITH) exhaust gas recirculation systems (EGR).
(20) Disconnect connector (A) generator and cable (IN).
(21) Disconnect connector (WITH) starter and cable (D).
(22) Disconnect connector (E) air compressor switch.
10. Remove protection (A) wiring harness.
Note: The high pressure fuel line must not be reused.
12. Remove valve (A) air control.
Note: Tightening torque: 8.8 - 10.8 Nm.
13. Remove the outlet (A) coolant.
Note: Tightening torque: 7.8 -11.8 Nm.
14. Remove the assembly (A) branch pipe of the exhaust gas recirculation system (EGR).
Note:
Torque:
- bolts (IN): 19.6 - 23.5 Nm.
- bolts (WITH): 9.8 - 11.8 Nm.
Before pipe installation (IN) exhaust gas recirculation systems (EGR) be sure to install the o-ring (A) into the intake manifold.
Attention. If, when installing the pipe of the exhaust gas recirculation system (EGR) O-ring is inserted into the intake manifold, it can be damaged, resulting in exhaust gas leakage.
15. Remove the intake manifold (A) with gasket (IN).
When installing the intake manifold, pre-tighten the bolts and nuts, then tighten them to the specified torque in the order shown.
Note: Tightening torque: 19.6 - 23.5 Nm.
Attention. Avoid getting foreign matter into the inlet.
16. Install in the reverse order of removal.