Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the air intake receiver.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
3. Remove the engine soundproofing cover.
TD6 ENGINE, REPAIR WORK, Engine soundproofing casing.
4. Disconnect the connector from the boost pressure sensor.
5. Loosen the bolt securing the vacuum tube to the intake manifold.
6. Remove the fuel pressure sensor harness bushing from the intake manifold.
7. Unclip the positive wire clamp from the intake manifold.
8. Loosen the bolt securing the oil dipstick bracket to the intake manifold.
9. Loosen the clamp and disconnect the air hose from the EGR valve. Remove and discard the clamp.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
10. Move the air intake hose to the side.
11. Disconnect the vacuum hose from the exhaust gas recirculation (EGR) valve.
12. Loosen the screw and remove the clamp securing the exhaust gas recirculation tube to the EGR valve.
13. Remove the rubber plugs from the intake manifold.
14. Unscrew the 12 bolts and 7 nuts securing the intake manifold.
15. Remove the intake manifold and discard its gaskets.
16. Close the cylinder head intake ports.
Assembly
1. Remove the plugs from the cylinder head intake ports.
2. Wipe the intake manifold and mating surface.
3. Wipe the flange of the EGR system pipe and the place where it connects to the valve of this system.
4. Install new gaskets on the intake manifold.
5. Install the intake manifold, install the noise-insulating casing mounting brackets on the bolts. Tighten the bolts and nuts evenly. The tightening torque for the bolts is 10 N·m, for the nuts - 15 N·m.
6. Install the rubber plugs.
7. Secure the fuel pressure sensor harness to the intake manifold.
8. Connect the connector to the boost pressure sensor.
9. Screw in the vacuum tube bracket mounting bolt and tighten it. Tightening torque 6 N·m.
10. Screw in the oil dipstick bracket mounting bolt and tighten it. Tightening torque 6 N·m.
11. Install the positive cable clamp to the intake manifold.
12. Install the EGR pipe clamp and tighten the screw.
13. Connect the vacuum hose to the EGR valve.
14. Clean the exhaust gas recirculation (EGR) valve spigot and the inlet hose connection.
15. Using a new clamp, secure the air inlet hose to the EGR valve. The clamp tightening torque is 6 N·m.
16. After waiting 10 minutes, tighten the clamp securing the air hose to the valve again. Tightening torque 6 N·m.
17. Install the soundproofing casing in place.
TD6 ENGINE, REPAIR WORK, Engine soundproofing casing.
18. Connect the negative battery terminal.
Comments on this article