Removing
1. Remove the high pressure fuel pump.
2. Remove the EGR cooler valve.
3. Disconnect connector (1) intake air sensor and connector (2) glow plugs.
4. Disconnect the cooling system connector.
5. Loosen the screw (1) cable bracket.
6. Disconnect the exhaust pipe, electrical connector (2), collar (3); remove the hose and unscrew the two bolts (4).
7. Remove quick connector (5) cooling systems.
8. Remove the oil seal from the cylinder block, undo the upper hose section (6), remove the clamp (7). Loosen two screws (8) and move the oil seal to the side.
9. Disconnect connector (1) exhaust gas recirculation drive.
10. Remove the pin (1) hold the high pressure fuel pump in place. To remove the stud, lock two M8 nuts.
11. Loosen the bolt (1) from the side of the lifting eye.
12. Loosen the fastening nuts (2) and remove the intake manifold.
Installation
1. Install intake manifold (2) with new seals. Tighten the fastening nuts to 25 Nm.
2. Install bolt (1) lifting eye.
3. Insert a hairpin (1).
4. Insert connector (1) exhaust gas recirculation drive.
5. Install the exhaust pipe and screw in two bolts (4). Install electrical connector (2), collar (3) and connect the hose.
6. Install the oil seal on the cylinder block, connect the upper hose connector (6), install clamps (7) and two bolts (8).
7. Install quick connector (5) cooling systems.
8. Install cable bracket (1).
9. Connect connector (1) intake air sensor and connectors (2) glow plug.
10. Install the exhaust gas recirculation cooler valve.
11. Install the high pressure fuel pump.
12. Connect the exhaust hose and start the engine. Check for leaks. Connect the diagnostic tool and clear the trouble codes from the vehicle's memory.
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