INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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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.

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

2.  Remove in the order indicated in the table.

3.  Install in the reverse order of removal.

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Fresh-air Duct Removal Note

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

1.  Remove the battery. (See BATTERY REMOVAL/INSTALLATION.)

2.  Remove the air inlet pipe.

Turbocharger Air Outlet Pipe Removal Note

1.  Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION.)

2.  Remove the turbocharger air outlet pipe.

Charge Air Cooler Inlet Hose Removal Note

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

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

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

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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 Removal Note

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

3.  Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

4.  Remove the EGR pipe. (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

5.  Remove the MAP sensor/IAT sensor No.2. (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR/INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

6.  Disconnect the water hose from the water outlet component.

7.  Disconnect the high fuel pressure sensor connector. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

8.  Disconnect the wiring harness clips from the intake manifold.

9.  Remove the intake manifold.

10.  Remove the bracket from the intake manifold.

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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 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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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.

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

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