Contents: Removal ⇓ Installation ⇓
1. Vacuum hose.
2. Air filter cover.
3. Air filter element.
4. Air intake.
5. Air filter housing.
6. Clamp.
7. Air hose.
8. Air intake duct.
9. Breather hose.
10. Turbocharger air inlet hose.
11. Electric heating.
12. Turbocharger air outlet duct.
13. Turbocharger air outlet hose.
14. Air intake duct.
15. Intercooler inlet hose.
16. Intercooler outlet hose.
17. Intake shut-off valve.
18. Intake manifold insulator.
19. Intake manifold.
20. EGR pipe (from the intake manifold side)
Note:replace the part with a new one after each removal.
Caution: A hot engine and intake system components can cause various burns. Turn off the engine and wait until it cools before removing intake system components.
Removal
1. Disconnect the negative battery terminal.
2. Disconnect the vacuum hose from the air cleaner cover.
3. Remove the MAF sensor/intake air temperature sensor #1.
4. Remove the air filter cover and take out the filter element.
5. Disconnect the air intake from the air filter housing by pressing the fasteners shown in the figure.
6. Remove the air filter housing.
7. Remove the air hose from the air filter cover.
8. Remove the battery.
9. Remove the air intake duct.
10. Remove the breather hose.
11. Remove the turbocharger air inlet hose.
12. Remove the electric heating.
13. Remove the battery tray.
14. Remove the turbocharger air outlet duct.
15. Remove the turbocharger air outlet hose.
16. Remove the air intake duct.
17. Release the retainer and remove the intercooler inlet hose as shown in the figure.
18. Release the connector retainer and remove the air outlet hose of the air intercooler.
19. Remove the inlet shut-off valve.
20. Loosen the bolts shown in the figure.
21. Remove the intake manifold insulator.
22. Disconnect the following connectors:
- Engine oil temperature/pressure sensor.
- Coolant temperature sensor.
- Manifold absolute pressure sensor No.2.
- Fuel pressure sensor.
- Fuel temperature sensor.
- Fuel pressure limiting valves.
- Glow plugs.
- Sensor No.2 of the intake air temperature.
- Camshaft position sensor.
- Exhaust gas recirculation system bypass valve.
- Starter.
23. Remove the wiring clamps, unscrew the bolts and nuts and remove the wiring bracket shown in the figure.
24. Disconnect the upper radiator hose from the intake manifold side.
25. Remove the EGR valve (exhaust gas recirculation systems).
26. Move the EGR cooler aside.
27. Move the EGR cooler bypass valve to the side.
28. Remove the intake manifold.
29. Remove the EGR pipe from the intake manifold.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
Installing the Intercooler Drain Hose
Install the air-to-air intercooler outlet hose as shown in the illustration.
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Installing the breather hose
Install the breather hose as shown in the figure.
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Installing the air hose
Install the air hose as shown in the figure.
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Installing the air filter housing
Install the air filter housing as shown in the figure.
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Installing the air intake
Install the air intake as shown in the figure.
Installing the air filter cover
Install the air filter cover as shown in the figure.
Secure the air filter cover to the housing with clamps.
Installing a vacuum hose
Install the vacuum hose as shown in the figure.
Article is available on the website [www.MAZbook.ru]
