Removal/Installation
WARNING: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Pressure Release Procedure".Fuel Pressure Release
REMOVAL/INSPECTION/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure.
Intake:
Legend
1. Dynamic Chamber Cover
2. Charge Air Cooler Air Duct
3. Air Cleaner Assembly
4. Air Duct
5. Fresh-Air Duct
6. Mass Air Flow Sensor
7. Air Intake Hose
8. Resonator
9. Charge Air Cooler (RH)
10. Charge Air Cooler (LH)
11. Air Hose
12. Accelerator Cable
13. EGR Valve
14. Air Intake Pipe Assembly
3. Visually check each part for damage. Replace if necessary.
4. Install in the reverse order of removal.
STEP 1
Dynamic Chamber Cover Removal Note
1. Remove nuts A.
2. Remove the dynamic chamber cover in the order shown.
Air Intake Pipe Assembly Removal/Installation Note
NOTE: Disassemble the air intake pipe assembly only when its component must be replaced or serviced. After necessary service has been completed, reassemble the components in the following procedure.
1. Install the mount rubber to the ABV actuator and the shutter valve body respectively.
Tightening torque: 19-25 Nm (14-18 ft.lbs.)
2. Install the shutter valve body, air intake pipe No.2, and ABV actuator to the intake manifold.
3. Tighten bolts and nuts A-F in order.
4. Temporarily loosen bolts and nuts marked B, C, and D, then retighten them in the order.
Tightening torque A-F: 19-25 Nm (14-18 ft.lbs.)
5. Install the air intake pipe No.1 and hand tighten bolts G.
6. Tighten nuts H, then tighten bolts G.
Tightening torque G and H: 7.9-10.7 Nm (70-95 in.lbs.)
Air Hose Installation Note
1. Install the clamps with their tabs facing as shown.
2. Before installing the charge air cooler side and middle clamps, tighten the flange side of the charge air cooler.
STEP 2
Fuel Hose Removal Note
Before disconnecting the fuel hoses, follow the "Fuel Pressure Release Procedure".
Coolant Hose Removal Note
Before disconnecting the coolant hoses, drain the coolant from radiator.
Lysholm Compressor Installation Note
Before installation, temporarily fix the rubber onto the Lysholm compressor with two-side adhesive tape.
Intake Manifold Assembly Installation Note
1. Install the intake manifold assembly with a new gaskets.
Torque Sequence:
2. Tighten the bolts and nuts in the order shown.
Tightening torque: 19-25 Nm (14-18 ft.lbs.)