INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Fuel injector ( 2pin type)

Fuel injector ( 6pin type)

Oil and Chemical Type

Warning

•  A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system.

Note

•  Rubber sealing (fluorine) for the connector part of the charge air cooler air inlet hose may be stuck. In addition, oil may be present on the sealing surface of the charge air cooler air inlet hose and charge air cooler air outlet hose. When replacing, always clean the sealing surface and inspect the hose inner surface.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Install in the reverse order of removal.

Fuel injector (2pin type)

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1	Vacuum hose (See Vacuum Hose Installation Note.)
2	Air cleaner cover (See Air Cleaner Cover Removal Note.) (See Air Cleaner Cover Installation Note.)
3	Air cleaner element
4	Fresh-air duct (See Fresh-air Duct Removal Note (Fuel injector (2pin type)).) (See Fresh-air Duct Installation Note.)
5	Air cleaner case (See Air Cleaner case installation note.)
6	Clip
7	Air hose (See Air Hose Installation Note.)
8	Air inlet pipe (See Air Inlet Pipe Removal Note (Fuel injector (2pin type)).)
9	Breather hose (See Breather Hose Installation Note (Fuel injector (2pin type)).)
10	Turbocharger air inlet hose
11	Blow-by heater (See BLOW-BY HEATER INSPECTION [SKYACTIV-D 2.2].)
12	Turbocharger air outlet pipe component (See Turbocharger Air Outlet Pipe Component Removal Note.)
13	Charge air cooler inlet hose (See Charge Air Cooler Inlet Hose Removal Note.) (See Charge Air Cooler Inlet Hose Installation Note.)
14	Hose clamp (See Hose Clamp Removal Note.) (See Hose Clamp Installation Note.)
15	Charge air cooler outlet hose (See Charge Air Cooler Outlet Hose Removal Note.) (See Charge Air Cooler Outlet Hose Installation Note.)
16	Intake shutter valve (See INTAKE SHUTTER VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
17	Intake manifold insulator (See Intake Manifold Insulator Removal Note (Fuel injector (2pin type)).)
18	Intake manifold (See Intake Manifold Removal Note (Fuel injector (2pin type)).)
19	EGR pipe (Intake manifold side) (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

Fuel injector (6pin type)

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1	Air cleaner cover (See Air Cleaner Cover Removal Note.) (See Air Cleaner Cover Installation Note.)
2	Air cleaner element
3	Fresh-air duct (See Fresh-air Duct Removal Note (Fuel injector (6pin type)).)
4	Air cleaner case (See Air Cleaner case installation note.)
5	Clip
6	Air hose (See Air Hose Installation Note.)
7	Air inlet pipe (See Air Inlet Pipe Removal Note (Fuel injector (6pin type)).)
8	Breather hose (See Breather Hose Removal Note.) (See Breather Hose Installation Note (Fuel injector (6pin type)).)
9	Turbocharger air inlet pipe
10	Blow-by heater (See BLOW-BY HEATER INSPECTION [SKYACTIV-D 2.2].)
11	Turbocharger air outlet pipe component
12	Charge air cooler inlet hose (See Charge Air Cooler Inlet Hose Removal Note.) (See Charge Air Cooler Inlet Hose Installation Note.)
13	Hose clamp (See Hose Clamp Removal Note.) (See Hose Clamp Installation Note.)
14	Charge air cooler outlet hose (See Charge Air Cooler Outlet Hose Removal Note.) (See Charge Air Cooler Outlet Hose Installation Note.)
15	Intake shutter valve (See INTAKE SHUTTER VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
16	Intake manifold insulator (See Intake Manifold Insulator Removal Note (Fuel injector (6pin type)).)
17	Intake manifold (See Intake Manifold Removal Note (Fuel injector (6pin type)).)
18	EGR pipe (Intake manifold side) (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

Air Cleaner Cover Removal Note

1.  Remove the MAF sensor/IAT sensor No.1. (See MASS AIR FLOW (MAF) SENSOR/INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the air cleaner cover.

Fresh-air Duct Removal Note (Fuel injector (2pin type))

1.  Pull out the fresh-air duct from the air cleaner case while pressing the tab shown in the figure.

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Fresh-air Duct Removal Note (Fuel injector (6pin type))

1.  While moving the tabs in the direction shown in the figure, rotate the fresh air duct.

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2.  Remove the fresh-air duct.

Air Inlet Pipe Removal Note (Fuel injector (2pin type))

1.  Remove the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the air inlet pipe.

Air Inlet Pipe Removal Note (Fuel injector (6pin type))

1.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the air inlet pipe.

Turbocharger Air Outlet Pipe Component Removal Note

1.  Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the turbocharger air outlet pipe component.

Breather Hose Removal Note

1.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the breather hose.

Charge Air Cooler Inlet Hose Removal Note

1.  Release the lock and remove the charge air cooler inlet hose as shown in the figure.

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Hose Clamp Removal Note

1.  Remove the front under cover No.1 and the front under cover No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

2.  Remove the hose clamp.

Charge Air Cooler Outlet Hose Removal Note

1.  Release the lock of connector and remove the charge air cooler outlet hose.

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Intake Manifold Insulator Removal Note (Fuel injector (2pin type))

1.  Remove the harness bracket shown in the figure.

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2.  Remove the bolts shown in the figure.

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3.  Remove the intake manifold insulator.

Intake Manifold Insulator Removal Note (Fuel injector (6pin type))

1.  Remove the adapter shown in the figure.

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2.  Remove the nuts shown in the figure.

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3.  Disconnect the IAT sensor No.2 connector. (See INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the bolts shown in the figure.

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5.  Disconnect the wiring harness clips shown in the figure.

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6.  Remove the bolts shown in the figure.

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7.  Remove the intake manifold insulator.

Intake Manifold Removal Note (Fuel injector (2pin type))

1.  Disconnect the connectors of the following parts:

•  Engine oil temperature sensor/engine oil pressure sensor (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  ECT sensor (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  MAP sensor No.2 (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Fuel pressure sensor (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Fuel temperature sensor (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Fuel pressure relief valve (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Glow plug short-cord (See GLOW PLUG REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  IAT sensor No.2 (See INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Camshaft position sensor (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  EGR cooler bypass valve (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Starter (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the wiring harness clips, bolts, nuts and harness bracket shown in the figure.

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3.  Disconnect the upper radiator hose from the intake manifold side.

4.  Remove the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Set the EGR cooler out of the way. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Set the EGR cooler bypass valve out of the way. (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

7.  Remove the intake manifold.

Intake Manifold Removal Note (Fuel injector (6pin type))

1.  Disconnect the connectors of the following parts:

•  Engine oil temperature sensor/engine oil pressure sensor (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  ECT sensor (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  MAP sensor No.2 (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Fuel pressure relief valve (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Glow plug short-cord (See GLOW PLUG REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  IAT sensor No.2 (See INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Camshaft position sensor (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  EGR cooler bypass valve (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Starter (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Compressor bypass solenoid valve (See COMPRESSOR BYPASS SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  EGR temperature sensor (With SCR system) (See EGR TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the wiring harness clips, bolts, nuts and harness bracket shown in the figure.

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3.  Remove the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Disconnect the upper radiator hose from the intake manifold side.

5.  Set the EGR cooler out of the way. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Set the EGR cooler bypass valve out of the way. (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

7.  Remove the intake manifold.

Charge Air Cooler Outlet Hose Installation Note

1.  Install the charge air cooler outlet hose as shown in the figure.

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Hose Clamp Installation Note

1.  Visually inspect the charge air cooler outlet hose and charge air cooler outlet pipe.

•  Replace damaged or cracked parts.

2.  Use a clean cloth to clean the outer surfaces of the charge air cooler outlet pipe and the inner surface of the charge air cooler outlet hose.

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3.  Temporarily install a new hose clamp to the charge air cooler outlet hose. (Do not tighten hose clamp)

Note

•  Installation can be facilitated by pointing the clamp in the direction shown in the figure.

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Caution

•  When installing the hose, do not apply oil to the area that was cleaned to prevent it from becoming disconnected.

4.  Insert the charge air cooler outlet hose until it contacts the charge air cooler outlet pipe stopper.

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5.  Re-position the temporarily installed hose clamp to the position 5—7 mm {0.20—0.27 in} from the charge air cooler outlet pipe stopper.

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Caution

•  If the hose clamp is not tightened sufficiently, the charge air cooler outlet hose could become disconnected, and if it is tightened excessively, it may damage the charge air cooler outlet hose and charge air cooler outlet pipe. Therefore, assemble the end of the hose clamp so that it rides on the white line.

6.  Tighten the hose clamp until the clamp end rides on top of the white line.

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7.  Install the front under cover No.1 and the front under cover No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

Charge Air Cooler Inlet Hose Installation Note

1.  Clean the seal surface and furrow area of the charge air cooler air inlet pipe and turbocharger air outlet pipe component.

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2.  Degrease the seal surface of the pipe, and verify if there is foreign matter penetration or scratches.

•  If there is foreign matter penetration or scratches, replace the pipe.

3.  Apply engine oil to the seal surface of the pipe.

Note

•  Make sure that the installation direction of the charge air cooler hose is correct and verify the marking shown in the figures.

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4.  Align the pipe rib and connector groove positions, and install.

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5.  Insert the pipe connector completely into the connector.

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6.  Pull the pipe outward and verify that a click sound is heard.

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Breather Hose Installation Note (Fuel injector (2pin type))

1.  Install the breather hose as shown in the figure.

Cylinder head cover side

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Blow-by heater side

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Breather Hose Installation Note (Fuel injector (6pin type))

1.  Install the breather hose as shown in the figure.

Cylinder head cover side

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Blow-by heater side

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Air Hose Installation Note

1.  Install the air hose as shown in the figure.

Air cleaner cover side

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Air inlet pipe side

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Air Cleaner case installation note

1.  Install the air cleaner case as shown in the figure.

Fuel injector (2pin type)

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Fuel injector (6pin type)

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Fresh-air Duct Installation Note

1.  Install the fresh-air duct as shown in the figure.

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Air Cleaner Cover Installation Note

1.  Install the air cleaner cover as shown in the figure.

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2.  Secure the air cleaner cover and the air cleaner case with the clip.

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Vacuum Hose Installation Note

1.  Install the vacuum hose as shown in the figure.

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