INTAKE SHUTTER VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

Gasket
 
Quantity: 1
 
Location of use: Intake shutter valve

Note
•  If the intake shutter valve is replaced, perform the “Operation After Replacing Intake Shutter Valve” procedure.

Operation After Replacing Intake Shutter Valve

1.  If the intake shutter valve is replaced, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Perform intake shutter valve initialization procedure.
(See INTAKE SHUTTER VALVE INITIALIZATION [SKYACTIV-D 2.2].)
2
Switch the ignition off.
—
3
Wait for 20 s. (Fuel injector (2pin type))
Wait for 30 s. (Fuel injector (6pin type))
—
4
Switch the ignition ON (engine off).
—
5
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
6
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)


Intake Shutter Valve Removal/Installation (Fuel injector (2pin type))

Warning
•  Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.
•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

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

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

3.  Remove the charge air cooler outlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the cooling system cap.

5.  Remove in the order shown in the figure.

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1
Intake shutter valve connector
2
Water hose No.1
(See Water hose No.1 removal note.)
(See Water hose No.1 installation note.)
3
Water hose No.2
(See Water hose No.2 removal note.)
(See Water hose No.2 installation note.)
4
Intake shutter valve
(See Operation After Replacing Intake Shutter Valve.)

6.  Install in the reverse order of removal.

7.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)


Water hose No.1 removal note

1.  Disconnect the water hose No.1 from the intake shutter valve and plug the water hose No.1 quickly.


Water hose No.2 removal note

1.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the starter terminal B cable installation nut.

3.  Detach the wiring harness clips shown in the figure.

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4.  Disconnect the water hose No.2 from the intake shutter valve and plug the water hose No.2 quickly.


Water hose No.2 installation note

1.  Install water hose No.2 as shown in the figure.

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Water hose No.1 installation note

1.  Install water hose No.1 as shown in the figure.

Intake shutter valve side

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Thermostat side

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Intake Shutter Valve Removal/Installation (Fuel injector (6pin type))

Warning
•  Never remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system.
•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

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

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

3.  Remove the charge air cooler outlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the cooling system cap.

5.  Remove in the order shown in the figure.

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1
Intake shutter valve connector
2
Water hose No.1
(See Water hose No.1 removal note.)
(See Water hose No.1 installation note.)
3
Water hose No.2
(See Water hose No.2 removal note.)
(See Water hose No.2 installation note.)
4
Intake shutter valve
(See Operation After Replacing Intake Shutter Valve.)

6.  Install in the reverse order of removal.

7.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)


Water hose No.1 removal note

1.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the terminal B cable installation nut of starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Disconnect the wiring harness clip shown in the figure.)

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4.  Disconnect the water hose No.1 from the intake shutter valve and plug the water hose No.1 quickly.


Water hose No.2 removal note

1.  Disconnect the water hose No.2 from the intake manifold and plug the intake manifold quickly.

2.  Remove the following parts as a single unit.

•  Intake shutter valve
•  Water hose No.1

3.  Remove the water hose No.2


Water hose No.2 installation note

1.  Install water hose No.2 as shown in the figure.

Intake shutter valve side

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Intake manifold side

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Water hose No.1 installation note

1.  Install water hose No.1 as shown in the figure.

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