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 inlet.
9. Breather hose.
10. Turbocharger air inlet hose.
11. Electric heating.
12. Turbocharger outlet duct.
13. Turbocharger air outlet hose.
14. Air inlet.
15. Intercooler inlet hose.
16. Outlet hose for intercooler.
17. Inlet shut-off valve.
18. Intake manifold insulator.
19. Intake manifold.
20. EGR pipe (co side intake manifold)
Note: replace the part with a new one after each removal.
Attention. A hot engine and intake system components can cause various burns. Shut off the engine and wait until it cools down before removing the intake system components.
Removing
1. Disconnect the negative battery terminal.
2. Disconnect the vacuum hose from the air filter cover.
3. Remove the mass air flow sensor / sensor No. 1 intake air temperature.
4. Remove the air filter cover and remove the filter element.
5. Disconnect the air intake from the air filter housing by pressing the tabs 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 intake duct.
10. Remove the breather hose.
11. Remove the turbocharger air inlet hose.
12. Remove electrical heating.
13. Remove the battery tray.
14. Remove the turbocharger outlet duct.
15. Remove the turbocharger air outlet hose.
16. Remove the intake duct.
17. To release a clamp and to remove an inlet hose of an intermediate cooler of air, as it is shown in drawing.
18. Release the connector retainer and remove the intercooler air outlet hose.
19. Remove the inlet shut-off valve.
20. Remove 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.
- Sensor No. 2 absolute pressure in the intake manifold.
- Fuel pressure sensor.
- Fuel temperature sensor.
- Fuel pressure relief valve.
- glow plugs.
- Sensor number 2 intake air temperature.
- Camshaft position sensor.
- Bypass valve of the exhaust gas recirculation system.
- starter.
23. Remove the wiring clamps, unscrew the bolts and nuts and remove the wire bracket shown in the figure.
24. Disconnect the upper radiator hose from the intake manifold.
25. Remove the EGR valve (exhaust gas recirculation systems).
26. Remove the EGR cooler to the side.
27. Remove the EGR cooler bypass valve to the side.
28. Remove 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 outlet hose
Install the intercooler outlet hose as shown.
Installing the breather hose
Install the breather hose as shown.
Air hose installation
Install the air hose as shown in the figure.
Installing the Air Filter Housing
Install the air filter housing as shown in the figure.
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 clips.
Vacuum hose installation
Install the vacuum hose as shown in the figure.