1.
Remove the engine cover (A).
Remove the engine cover (A).
Remove the under cover (A).
Loosen the radiator drain plug (A) and drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the air cleaner assembly.
Remove the air duct (A).
Disconnect the air flow sensor (AFS) connector (B).
Disconnect the breather hose (C).
Remove the intake air hose (D) and air cleaner assembly (E).
Tightening torque :
Clamps: 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Bolts: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Disconnect the terminals (A) from the battery and remove the battery (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Remove the battery tray (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Disconnect the intake air temperature sensor connector (A) and remove the intercooler inlet pipe&hose (B) and outlet pipe&hose (C).
Tightening torque :
Clamps: 4.9 ~ 6.9N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)
Bolt: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Disconnect the boost pressure sensor (BPS) connector (A) and remove the intercooler inlet pipe & hose (B) and outlet pipe & hose (C).
Remove the upper radiator hose (A) and lower radiator hose (B).
Disconnect the engine wire harness connectors and remove the wire harness clamps from the cylinder head cover and the intake manifold.
Disconnect the difference pressure sensor connector (A). (With DPF) [Euro - 5 only]
Disconnect the exhaust gas temperature sensor connector (B). (With DPF) [Euro - 5 only]
Disconnect the lambda sensor connector (C). [Euro - 4/5 only]
Disconnect the cam position sensor (CMPS) connector (A).
Disconnect the rail pressure sensor connector (B).
Disconnect the glow plug connector (C).
Disconnect the fuel pressure regulator valve connector (D).
Disconnect the boost pressure sensor (BPS) connector (E).[2.2L only]
Disconnect the oil pressure switch connector (F).
Disconnect the crankshaft position sensor (CKPS) connector (G).
Disconnect the EGR cooling valve connector (H). [Euro - 4/5 only]
Disconnect the fuel temperature sensor connector (I).
Disconnect the rail pressure regulator valve connector (J).
Disconnect the injector connectors (K).
Disconnect the air control valve connector (L).
Disconnect the variable swirl control actuator connector (A). [Euro - 4/5 only]
Disconnect the engine coolant temperature sensor (ECTS) connector (B).
Disconnect the E-VGT actuator connector (C).
Disconnect the EGR actuator connector (D).
Disconnect the alternator connector (A) and the cable (B).
Disconnect the starter connector (C) and the cable (D).
Disconnect the air compressor switch connector (E).
Remove the wire harness protector (A).
Disconnect the fuel hose (A), the high pressure pipes (B), and EGR vacuum hose (C) [Euro - 4/5 only]. (Refer to FL group)
Do not reuse the high pressure pipe.
Remove the air control valve (A).
Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)
Remove the water outlet pipe (A).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Remove the EGR pipe assembly (A). [Euro - 4/5 only]
Tightening torque :
Bolts(B): 19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)
Bolts(C): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
When installing the EGR pipe assembly, make sure to insert the O-ring(A) to intake manifold before installing EGR pipe(B).
If installing an EGR pipe with O-ring inserted to the intake manifold, the O-ring may be damaged and this can cause an exhaust gas leakage.
Remove the intake manifold (A) with the gasket (B).
When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
Tightening torque :
19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)
Be careful not to have a foreign substance come into the inlet port.
Installation is the reverse order of removal.
