Intake Manifold - Removal

REMOVAL

1. Disconnect negative battery cable.
2. Remove the engine cover.Access Cover
3. Drain the cooling system.
4. Remove the coolant reservoir an position aside.
5. Remove the strut tower support.





6. Remove the air cleaner housing cover and air inlet tube (1).
7. Remove the charge air outlet tube (4).
8. Remove the right rear engine cover bracket and disconnect the transmission oil level indicator tube retaining bolt.
9. Remove the turbo charger.Turbocharger - Removal

CAUTION: Observe the position of the turbocharger oil passage housing and gasket. Failure to properly position the gasket during assembly will result in immediate turbocharger failure after assembly.





10. Remove the turbocharger oil housing adaptor (1) and gasket.
11. Remove the EGR tube to the left cylinder head.
12. Disconnect the coolant hose at the EGR housing.
13. Disconnect the EGR and EGR temperature sensor wiring harness connectors.
14. Disconnect the swirl valve module wiring harness connector.
15. Remove the left fuel rail and high pressure lines.
16. Remove the right fuel rail and high pressure lines.
17. Disconnect the fuel return hoses at the injectors.
18. Disconnect the return fuel hose harness and position aside.
19. Remove fuel rail transfer line.
20. Remove the fuel filter assembly.
21. Remove the fuel filter supply and return pipe harness and position aside.
22. Remove the glow plug module.
23. Remove the EGR air control valve assembly.

CAUTION: Do Not rest the intake manifold on the swirl valve actuator. Care must be taken when handling the swirl valve assembly.

24. Remove the intake manifold and gasket.