INTAKE SYSTEM

1719-00

INTAKE SYSTEM

GENERAL INFORMATION

1. SPECIFICATION.................................... 3
2. INSPECTION.......................................... 4

OVERVIEW AND OPERATING

PROCESS
1. OVERVIEW............................................ 6
2. COMPONENT........................................ 6
3. INPUT/OUTPUT DEVICES..................... 8
4. OPERATING PROCESS......................... 9
5. WIRING DIAGRAM................................. 10

CONFIGURATION AND FUNCTION

2313-01 AIR CLEAR ASSEMBLY............... 11

2330-01 INTERCOOLER............................ 12
1719-01 INTAKE MANIFOLD..................... 13

REMOVAL AND INSTALLATION

2313-01 COMPONENT.............................. 14
2313-01 AIR CLEAR................................... 17
2330-01 INTERCOOLER............................ 19
1719-01 INTAKE MANIFOLD ASSEMBLY
..................................................... 21
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INTAKE SYSTEM
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INTAKE SYSTEM 1719-00

GENERAL INFORMATION
1. SPECIFICATION
Component Item Specification
Air cleaner element Filter type Dry, filter element
Filter area 0.64 m²
Replace interval EU change every 20000 km or
12months
(But, shorten the service interval
under severe conditions)

GEN change every 15000 km or

12months
(But, shorten the service interval
under severe conditions)

Air cleaner assembly Weight 1.13 kg

Operating temperature -30 ~ 100℃
Capacity 6.5 L
Intercooler Core material Aluminum
Size 510 x 110 x 70 (W x H x T)
Core size 510 x 110 x 63 (W x H x T)
Tank material Plastic (Molding)
Efficiency 80%

* Shorten the service interval under severe conditions such as driving on a dusty road or off-
road.

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Component Item Specification

Air cleaner element Filter type Dry, filter element
Filter area 0.64 m²
Replace interval EU change every 20000 km or
12months
(But, shorten the service interval
under severe conditions)

GEN change every 15000 km or

12months
(But, shorten the service interval
under severe conditions)

Change at every 30,000 km of driving.

Air cleaner assembly Weight 1.13 kg
Operating temperature -30 ~ 100℃
Capacity 6.5 L
Intercooler Core material Aluminum
Size 510 x 110 x 70 (W x H x T)
Core size 510 x 110 x 63 (W x H x T)
Tank material Plastic (Molding)
Efficiency 80%

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2. INSPECTION
1) Troubleshooting
▶ When Abnormal Noises are Heard from the Engine Room

For the vehicle equipped with DI engine, if a learning noise occurs in each range or other
noises occur, the major cause of it is a faulty turbocharger assembly. But an interference
issue, poor tightness or loose in the intake and exhaust system also can cause those
noises. This is mainly because the operator didn't follow the instruction exactly when
reconnecting the intake hoses and pipes which were disconnected to check the system or
replace the air cleaner. If the intake system is free of any faults, check the EGR and PCV oil
separator connected to the intake system.
The figure may be different from the actual engine. Therefore, read thoroughly below before
replacing the parts.

2) Abnormal Noise Caused by Poor Tightness of Intake System

When the DI engine is running, the air entered into the engine flows in the sequence as shown
above. If high intake pressure is applied to the loose or damaged part, a whistling noise may
occur, the intake air volume is measured incorrectly or the engine power is derated.

INTAKE SYSTEM
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3) Troubleshooting Sequence
The basic checks for intake system are as follows:

▶ Basic Checks for Intake System

Make sure to replace or clean the air

cleaner element periodically. Otherwise,
engine will be derated or work abnormally
because of low intake air volume.
Unlike the fuel system, which is a closed
circuit, the intake system is an open circuit
system. Therefore any malfunction may
occur due to dust and dirt.
Most of the connections consist of hoses
so the system cannot withstand high
temperature and pressure. Also it can be
deformed or loosened easily because it is
a clamp mounting system. Thus, when
checking the engine, basic inspections,
such as tightened status check and visual
inspection for hose, etc., should be carried
out in advance.

▶ Other Checks for Intake System

If the intake system is free of any faults,

check for EGR and PCV oil separator.

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OVERVIEW AND OPERATING PROCESS

1. OVERVIEW
The intake system for D20DTF engine is equipped with a throttle body which includes a flap.
This flap is controlled by an electrical signal to cut off the intake air entering to the engine when
the ignition switch is turned off. Because of this, the shape of the intake manifold has been
changed and improved HFM sensor is newly adopted to control the intake air volume more
precisely.

2. COMPONENT
1719-02 Swirl control valve

Works variably in accordance with the

engine load and rpm.
* For more information, refer to
"Engine Control" section.

1719-01 Intake manifold

1719-16 Electric throttle body

Passage for variable swirl valve

and for intake air

* For more information, refer to "Engine

Control" section.

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2313-15 HFM sensor

HFM sensor, version 6

* For more information, refer to "Engine
Control" section.

2313-01 Air cleaner assembly and

resonator

2330-01 Intercooler assembly

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3. INPUT/OUTPUT DEVICES

ECU (DCM 3.7)

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4. OPERATING PROCESS

▶ Work Flow

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5. WIRING DIAGRAM

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CONFIGURATION AND FUNCTION

2313-01 AIR CLEANER ASSEMBLY

Shorten the service interval under excessive use or severe conditions such as driving on a
dusty road or off-road, or driving in the rain.

Vehicle symptoms if service interval is not kept

- Insufficient engine power
- Excessive emissions
- Prematurely worn engine cylinder wall, piston, piston ring and intake valve

1) Overview
The element of the air cleaner element filters
the intake air through the dry paper to
protect the engine and seal the air cleaner.

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2330-01 INTERCOOLER
1) Overview
The turbocharger is designed to improve the engine power by introducing more air (oxygen)
into the cylinder with rotational power of the turbine generated from the exhaust pressure.
However, the intake air is heated during the compression process in the turbocharger
compressor and this leads to a lower air density.
In other words, the intercooler is needed to minimize the loss of turbocharger efficiency due to
heat expansion. The intercooler is a device which cools down (20 to 60°C) the hot air (60
~ 160°C) entering the engine to improve the turbocharging efficiency.
Thus, more air is entered into the cylinder and more power is produced than the engine with
turbocharger only.

2) Component

Air cleaner assembly

Hose (connects
air cleaner and
turbocharger)

Duct assembly (connects Snorkle

turbocharger and intercooler)

Intercooler assembly

Resonator assembly
Hose (connects
intercooler and engine)

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1719-01 INTAKE MANIFOLD

1) Overview
The intake manifold assembly is designed to optimize the mixture of the EGR gas in the intake
chamber when the compressed air in the turbocharger is sent to the intake port. The intake port
is a dual-type port (tangential and helical port) which increases the swirl ratio in mid/low
operating range to improve the acceleration/fuel economy and to decrease the particle matters.

Always replace the removed gasket with a new one and tighten it with the specified torque
(25 ±2.5 Nm).

The intake manifold gasket is coated with NBR elastomeric on the SUS to maximize the sealing
effect.

2) Mounting Location

Intake manifold

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REMOVAL AND INSTALLATION

2313-01 COMPONENT
1) Air Cleaner

2313

1. Air cleaner assembly 12.Snorkel assembly

3. Element assembly 13.Protector - Water
5. Insulator - Air cleaner mounting No.2 14.Resonator assembly
6. Collar - Insulation 15.Meter - Air mass
7. Clamp - Spring 16.O-ring
8. Duct - Resonance 17.Screw rivet - RR fascia MTG
9. O-ring - Resonance 18.Bolt
10.Insulator - Air cleaner mounting No.1 19.Nut
11.Bracket - Air cleaner mounting 20.Screw

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2) Intercooler

2330

1. Intercooler assembly 11.Hose - Intercooler to engine

2. Hose assembly - Air clear to turbocharger 12.Clamp - Worm drive type spring
3. Hose - Turbocharger to intercooler 13.Bracket assembly - Hose mounting
4. Duct - Turbocharger to intercooler 14.Nut
5. Hose - Turbocharger to intercooler 15.Clamp - Spring
6. Bracket - Intercooler mounting 16.Screw
7. Clamp - Worm drive type spring
8. Clamp - Spring
9. Hose - Intercooler outlet
10.Duct - Intercooler to engine

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3) Intake Manifold Assembly

1719

1. Manifold - Intake 16.Electric throttle body

2. Valve assembly - Swirl control 17.Bolt
5. Gasket - Intake manifold 29.Duct - Intake
6. Bolt 30.Gasket - Intake duct
8. Bolt 31.Bracket - Intake duct
9. Cover assembly - Acoustic 32.Bolt
10.Bolt

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2313-01 AIR CLEANER

Disconnect the negative cable from the battery.

1 1. Disconnect the HFM sensor connector (A).

2. Disengage the clamp (B) and disconnect
the intake hose.

3 3. Remove the air cleaner upper housing by

lifting in the direction (A) shown in the
figure.

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4. Remove the air cleaner element from the

4
air cleaner housing.

Check that the air cleaner element is

clogged, contaminated or damaged. If
the element is clogged a little bit, remove
the foreign material using compressed
air from the back side of the element.
Replace the element if it is excessively
contaminated. Do not allow any foreign
matter to enter into the system when
replacing.

- Make sure to replace the air cleaner

element with a genuine part.
- Blow the compressed air to the opposite
side of the air intake side to remove the
foreign material on the air cleaner. If
blow the air in the opposite direction the
foreign material can be entered into the
engine.

5. Install in the reverse order of removal.

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2330-01 INTERCOOLER
- Disconnect the negative cable from the battery.
- Remove the acoustic cover.
- Remove the air cleaner upper housing.

1. Disengage the intercooler inlet (A) and

1
outlet (B) hose clamps.

2 2. Remove the air cleaner assembly lower

housing.
a. Unscrew the bolt (A).
b. Remove the air cleaner mountings (B).

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3. Unscrew the mounting bolts (A) and (B) for

3
the intercooler.

25 ± 2.5 Nm

4. Pull the inlet of the intercooler in the

4
direction (A) a little bit, and then remove
the intercooler assembly by pulling it in
the direction (C).

Because the intercooler and the flexible

intake insert are mounted with pins, it is
important to be extra careful when
removing and installing them.

5. Install in the reverse order of removal.

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1719-01 INTAKE MANIFOLD ASSEMBLY

The throttle body is removed (see 1719-16).

1. Unplug the drain cock at the bottom of the

1
radiator to drain the coolant completely.

- Never open the cap if the coolant

temperature is more than 90℃
(194℉) to prevent any burn.
- Drain the coolant into a suitable
container and do not spill it on the floor.
- Avoid the coolant to come in contact
with your skin or the vehicle body as
anti-freeze is included. In case of skin
contact, wash thoroughly with plenty of
clean water immediately.
- The coolant to be replaced or added
should be original coolant with the same
specifications.

2. Remove the engine wire harness

connectors.

Variable swirl valve

EGR valve
EGR bypass valve
Alternator (+) and connector
A/C compressor connector
CPS (Crankshaft position sensor)
connector
T-MAP sensor connector
Electric throttle body connector
Knock sensor connector

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3. Unscrew the bolts (A) and bolts (B), and

3
remove the EGR pipe.

25 ± 2.5 Nm
10 ± 1.0 Nm

- Always replace the used gasket for the

EGR cooler pipe with a new one,
because the used one can be deformed
by heat and can cause a leak.
- Make sure the installation direction of the
gasket is correct.

4. Unscrew the bolt (A) to remove the intake

4
duct mounting bracket.

25 ± 2.5 Nm

5. Unscrew the bolts (A) and remove the

5
intake duct.

25 ± 2.5 Nm

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6. Remove the E-EGR cooler.

6
a. Disengage the clamp and disconnect the
E-EGR cooler outlet hose (A).
b. Unscrew the mounting bolts (B) of the
EGR cooler.

Avoid the coolant to come in contact with

your skin or the vehicle body as anti-
freeze is included.

c. Unscrew the bolts (C) and remove the

EGR cooler.

Disconnecting the vacuum hose

7
7. Remove the E-EGR valve.
a. Disconnect the E-EGR valve cooler hose
(A).

b. Unscrew the 3 bolts (13 mm) and remove

the E-EGR valve assembly.

25 ± 2.5 Nm

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8. Unscrew the 8 bolts (13 mm) to remove

8
the intake manifold.

25 ± 2.5 Nm

- Replace the gasket with a new one.

Unscrew the bolts slowly in two or more
- stages to prevent distortion of the intake
manifold and cylinder head.

9. Unscrew the mounting bolts for the intake manifold in the sequence shown in the figure below.

When installing the intake manifold, tighten the bolts in the reverse order of removal in 2
or 3 steps with the specified torque.

10. Install in the reverse order of removal.

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