DI03-1

SECTION
00 DI03

INTAKE SYSTEM

Table of Contents

AIR FLOWS ................................................................. DI03-3

INTAKE SYSTEM LAYOUT ......................................... DI03-4

Components locator ............................................... DI03-4
Air cleaner ............................................................... DI03-5
Air flow sensor
(hot film air mass sensor) ....................................... DI03-8
Intercooler ............................................................. DI03-14
Intake manifold assembly ..................................... DI03-16
SPECIAL TOOLS AND EQUIPMENT ........................ DI03-17

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
 DI03-3

AIR FLOWS

Intake Valve
(in combustion chamber)

Intake Manifold

Air Cleaner

Turbo
Charger Engine

HFM Sensor

Intake Air Outlet Hose Intercooler Intake Air Inlet Hose

Y220_03001

Work Flow of Intake System

Combustion
Air HFM Turbo Intake
Intercooler Chamber in
Cleaner Sensor Charger Manifold
Engine

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-4

INTAKE SYSTEM LAYOUT

COMPONENTS LOCATOR

Air cleaner Intake manifold

HFM sensor Intercooler

Y220_03002

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-5

AIR CLEANER

Cover

Element

Housing

Y220_03003

Specifications
Element Type Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-6

Air Cleaner Element - Replacement

Preceding Work: Disconnection of negative battery cable

1. Disconnect the HFM sensor connector.

2. Loosen the locking clamp and remove the intake duct.

Y220_03004

3. Unscrew the screws and remove the air cleaner cover.

Y220_03005

4. Remove the air cleaner element. Clean or replace the

element as required.

Y220_03006

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-7

Air Cleaner Housing

- Removal and Installation
Preceding Work: Removal of air cleaner cover

1. Set aside the return hose and remove the coolant reservoir
bolts.

Y220_03007

2. Remove the air cleaner housing bolts.

3. Install in the reverse order of removal.

Y220_03008

Air Cleaner Housing/Element - Check

1. Check the air cleaner body, cover and packing for
deformation, corrosion and damage.
2. Check the air duct for damage.

Y220_03009

3. Check the air cleaner element for clogging, contamination

and damage. If the element is partially clogged, remove
the dust or foreign materials with the compressed air. If
the contamination is severe, replace it with new one. Also,
be careful not to contaminate during the replacement.
4. Check the air cleaner housing for clogging, contamination
and damage.
5. If the inside of housing is contaminated, remove the
contaminants.
Notice
When cleaning the air cleaner with compressed air,
direct the air from inside (engine) to outside (ambient
air). Otherwise, contaminants can get into the engine. Y220_03010

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-8

AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)

Change history
inner tube added + grid (No.3)
added + sensing chip changed +
sensing section design changed

Results
Durability has enhanced 60
times (lab test results)

<CI type HFM sensor structure>

Y220_03011

1. Plug-in sensor 7. Hybrid

2. Cylinder housing 8. Sensor
3. Protection grid 9. Mounting plate
4. Hybrid cover 10. O-ring
5. Measuring duct cover 11. Temperature sensor
6. Housing

Air flow sensor is locating on the air intake passage between air cleaner and intake manifold and measures air volume
flows to engine combustion chamber and intake air temperature.
And intake temperature sensor built-in the sensor detects intake temperature.
Internal circuit of the air flow sensor is being used to control the voltage value to control the temperature to maintain the
heating resistance (Rh) to 160°C that is higher temperature than intake air temperature that is measured by resistance
(RI).
Temperature sensor of the heating resistance (Rh) is measured by resistance (Rs).
If temperature changes occur due to increasing/decreasing intake air volume, voltage of the heating resistance changes
to maintain the intake air temperature changes to set value (160°C).
Control unit computes intake air volume based on voltage changes of heating resistance.
Intake air temperature is measured by NTC integrated in the sensor.

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-9

Intake air temperature sensor is a part of HFM sensor and a thermister and resister and detects air temperature
changes that flow into the engine. There occurs high resistance when temperature is low and low resistance when high
(NTC type).
ECU supplies 5 V to intake air temperature sensor and then measures voltage changes to determine the intake air
temperature. When air in the intake manifold is cold, the voltage is high and air is hot, the voltage is low.
The reason for using HFM sensor is that this sensor is most proper in controlling accurate air-fuel ratio to meet the legal
emission regulations. This sensor measures actual intake air mass into engine very accurately during specific instant
acceleration and deceleration, and determines engine loads and detects intake air pulsation and air flows.

Main functions of HFM sensor are:

• Using for EGR feedback control
• Using for turbocharger booster pressure control valve control
• Using for fuel injecting compensation
CI type HFM sensor: The air flowing the sensor does not directs toward sensing section but flows along with lower wall
after passing protection grid to enhance durability of the sensor. Oil, water and dust less damage the sensor.

Air outlet Air inlet

<Structure of CI type HFM sensor>

Y220_03012

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-10

Power supply

Intake air
flow
sensor

Ground

Ground

Signal

Intake air temperature

sensor
HFM sensor

<Circuit diagram of HFM sensor>

Y220_03013

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-11

HFM Sensor - Removal and Installation

HFM sensor

Y220_03014

Preceding Work: Disconnection of negative battery cable

1. Disconnect the negative battery cable.

2. Loosen the clamps on the air cleaner and the turbo
charger and remove the duct.

Y220_03015

3. Unscrew the bolts and remove the HFM sensor assembly.

Tightening torque 10 ± 1.0 Nm

Y220_03016

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-12

4. Install in the reverse order of removal.

Y220_03017

Intake Air Outlet Hose (Turbo Charger)

- Removal and Installation
1. Remove the radiator grille.

Y220_03018

2. Loosen the clamp at both sides and remove the outlet

hose.

Y220_03019

3. Loosen the clamp on the intake air hose and remove the
intake air hose.
Installation Notice

Tightening torque 6 ~ 7 Nm

4. Install in the reverse order of removal.

Notice

Securely fasten the clamps on the pipes and hoses.

Y220_03020

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-13

Intake Air Inlet Duct (Air Cleaner)

- Removal and Installation
1. Loosen the clamp at intercooler side.
2. Loosen the clamp at turbo charger side.

Y220_03021

3. Separate the hose from the oil separator and remove the
intake duct.
4. Install in the reverse order of removal.

Y220_03022

Intake Air Inlet Duct (Intake Manifold)

- Removal and Installation
1. Loosen the clamp on the inlet hose in intercooler.

Y220_03023

2. Loosen the clamp at the intake manifold and remove the

inlet hose.
Installation Notice

Tightening torque 6 ~ 7 Nm

3. Install in the reverse order of removal.

Y220_03024

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-14

INTERCOOLER
The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine. However,
the intake air is heated (100 ~ 110°C) during the compression process in turbo charger compressor and the density is
lowered.
The intercooler is the device which cools (50 ~ 60°C) the air entering the engine. Colder air has more oxygen molecules
than warm air. Thus cooler air gives more power and better fuel economy.

Y220_03025

1. Intercooler

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-15

Intercooler - Removal and Installation

1. Remove the radiator grille.

Y220_03018

2. Loosen the clamp at both sides (inlet and outlet) of the

intercooler.
Installation Notice

Tightening torque 6 ~ 7 Nm

Y220_03027

3. Remove the intercooler mounting bolts.

Installation Notice

Tightening torque 10 ± 1.0 Nm

Y220_03028

4. Remove the air duct in intake manifold and the intercooler

assembly.

5. Install in the reverse order of removal. Y220_03029

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-16

INTAKE MANIFOLD ASSEMBLY

Y220_03030

System Characteristics
• Shape that delivers the required capacity of compressed air from turbo charger to inlet port
• Optimized EGR gas mixture in inlet chamber
• Maximized intake efficiency with helical and tangential inlet port
- Improving the swirl ratio in low and mid operating range
- Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range
• Integrated inlet port and coolant outlet port

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-17

SPECIAL TOOLS AND EQUIPMENT

Name and Part Number Application

Intake manifold locking guide pin Installation of intake manifold

Y220_03031 Y220_03032

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-18

Intake Manifold - Removal/Installation

Preceding Work: Disconnection of negative battery cable

1. Lift up the vehicle and remove the skid plate.

Y220_03033

2. Open the coolant reservoir cap and remove loosen the

drain cock to drain the coolant.

Y220_03034

3. Remove the air inlet hose (1) from intake manifold.

4. Loosen the clamp and remove the coolant inlet hose (2).

Y220_03035

5. Remove the coolant inlet port housing.

6. Remove the vacuum hose from EGR valve.
7. Remove the EGR valve mounting bolts and gasket.
Remove the EGR exhaust pipe (primary) mounting bolts
and gasket.

Notice

• Replace the pipes (2, 3) at both sides of EGR cooler

(1) and gaskets with new ones.
• Make sure that the convex surface of gasket is facing
to the pressurized direction.
Y220_03036

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN
 DI03-19

8. Remove the brackets and connectors from top section of

the engine.
- Vacuum hose bracket in turbo charger
- Booster pressure sensor
- Main wiring bracket
- Ground cable bracket
- Fuel pressure sensor connector
9. Unscrew the bolts and remove the vacuum modulator
bracket.

Tightening torque 9.0 Nm

Y220_03037

10. Remove the HP pump fuel supply line bolts.

11. Remove the HP pump fuel supply line mounting bracket.
12. Remove the HP pump fuel return line at fuel filter.

Notice

• Plug the openings of pipes and ports with sealing

caps to keep the cleanness of the fuel system.
• Replace the pipes with new one once removed.

Y220_03038

13. Remove the injector return line at HP pump.

Notice

• Be careful not to damage the pipes to HP pump.

• Plug the fuel return port of the HP pump with a
sealing cap.

Y220_03039

INTAKE SYSTEM CHANGED BY

DI ENG SM - 2004.4 EFFECTIVE DATE
AFFECTED VIN
DI03-20

14. Remove the intake manifold mounting bolts.

Notice

1. Check the length of the bolts before installation.

M8 x 45: 6EA
M8 x 130: 6EA

Tightening torque 25 ± 2.5 Nm

Y220_03040

15. Lift up the vehicle and remove the propeller shaft joint
bolts.
16. Unscrew the bolt in oil filter and remove the intake
manifold and gasket.

Notice
• Replace the gasket with new one.
• Make sure that the residual coolant in intake
manifold gets into the inside of inlet port.

Y220_03041 17. Install in the reverse order of removal.

Notice
• Replace the gasket with new one.
• If replaced only gasket without any other service
operation, completely remove the coolant and other
contaminants from the engine before installation.

CHANGED BY INTAKE SYSTEM

EFFECTIVE DATE DI ENG SM - 2004.4
AFFECTED VIN