MAN-00162

Repair Manual Air Intake System Nov 2011/ Rev 2

AIR INTAKE SYSTEM

CONTENTS

Description and Operation ..............................................................1

Crankcase Ventilation System Layout ............................................... 2

Component Location Index............................................................. 3

Service Tips and Precautions .........................................................4

Incar Repairs ....................................................................................5

Air Cleaner Duct - Dirty Side .......................................................5

Removal ............................................................................................. 5
Installation ........................................................................................... 6

Air Filter Element ..........................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 7

Air Filter Housing .........................................................................8

Removal ............................................................................................. 8
Installation .......................................................................................... 8

Air Cleaner Outlet Hose - Clean Side .........................................9

Removal ............................................................................................. 9
Installation .......................................................................................... 9

Oil Separator ..............................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 11

Oil Separator Hose .....................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 12

HFM Sensor ................................................................................ 12

Removal ........................................................................................... 12
Installation ........................................................................................ 13

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake System Nov 2011/ Rev 2

Boost Pressure Sensor ............................................................. 13

Removal ........................................................................................... 13
Installation ........................................................................................ 14

NVH Cover .................................................................................. 14

Removal ........................................................................................... 14
Installation ........................................................................................ 14

Intercooler ................................................................................. 15
Removal ........................................................................................... 15
Installation ........................................................................................ 16

Intercooler Inlet Hose ................................................................ 16

Removal ........................................................................................... 16
Installation ........................................................................................ 17

Intercooler Outlet Hose ............................................................. 17

Removal ........................................................................................... 17
Installation ......................................................................................... 18

Intercooler Bracket ................................................................... 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18

Diagnostics and Testing ............................................................... 19

Troubleshooting Chart...................................................................... 19
Component Inspection and Action Table ......................................... 21

Technical Specification ................................................................ 21

Torque Specification ..................................................................... 21

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Air Intake System

Description and Operation

Air Intake
Duct

Air Filter
Mass Air Flow
Sensor

Exhaust Gas To
Catalytic Converter
Turbo
Charger
Exhaust Manifold
Intercooler

Engine

Inlet Manifold
Boost
Pressuer
Sensor
EGR Cooler
EGR Valve

By virtue of suction created in the system, air is EGR (Exhaust Gas Recirculation) system is used to
sucked through the intake hose. The unfiltered air reduce the NOx emission levels. A part of the
enters the air cleaner housing at the bottom and exhaust gas is tapped from the exhaust manifold
leaves through the top after passing through a filter and made to mix with the air coming from the
element. The filter element has multiple filtering intercooler before entering the intake manifold.
media layers which have different porosities and Theses exhaust gases from EGR is made to pass
cleaning efficiencies. Dust and other fine particles through a cooler called EGR Cooler before allowing
are sucked inside along with air get trapped in the it to mix with air coming from intercooler.
air cleaner while passing through the filter element.
A Hot Film air Mass Flow rate (HFM) sensor is
attached to an outlet of the air cleaner. Clean air
coming out of the air cleaner passes through the
sensor mounted on the air cleaner housing. The
HFM sensor measures the air mass, flow rate and
temperature of air inside the system.
The filtered air enters the turbocharger (VGT type)
where the air is compressed. The heated com-
pressed air then passes through the intercooler
where the heat gets dissipated. From here it is drawn
into the intake manifold and into the engine.
The Variable Geometry Turbocharger (VGT) controls
the boost pressure. The boost temperature sensor
fitted on the outlet hose of the intercooler unit mea-
sures the boost pressure. The boost signal is given
to the ECU. Based on the load, engine speed and
temperature, the ECU controls the boost pressure by
manipulating the VGT.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-1
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Crankcase Ventilation System Layout

Fresh Air
From Air Filter

To Intake Manifold
Turbocharger

Cylinder Head Cover Oil

Seperator
Cylinder Head

Cylinder Block

Sump

In order to reduce the blow by gas emission, the blow

by gas is directed to the intake manifold through the
oil separator which separates the oil from the blow by
gas and allows the air to pass to the intake manifold.
Blow by gases are drawn from crankcase and
cylinder head cover.
Certain amount of oil will be carried from the oil
separator to the Air inlet hose, which is normal.
However if it is excessive please look for all the
causes mentioned in the high blow-by.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-2 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Component Location Index

D
A
E

B
C

A. Air Cleaner Assembly D. Clean Side Hose

B. Dirty Side Duct E. Oil Separator Hose
C. HMF Sensor

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-3
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Service Tips and Precautions • Check the oil separator system, in particular for
any leak in vacuum leak. As any vacuum leak
Observe the following precautions when disassem- will lead to a high pressure build up and then it
bling and servicing the air intake system and its ele- will go through the intake system and give a sig-
ments. nal of high blow by or be confused with com-
pressor oil leak.
• Always wear hand gloves before starting any
servicing. • Do not place any tool or parts over the inter-
cooler as it will damage the fins which will lead
• Stay clear of rotating vehicle parts. reduced performance of intercooler.
• Stay clear of hot vehicle parts.
• Avoid repeated contact with fluids.
• Do not let fuel, coolant and other fluids to spill CAUTION
over electrical and hot vehicle parts. Replace air filter element every 40,000 kms
• Before removing and servicing, clean the outer under normal operating conditions. Under
surface of the parts. Highly dusty or polluting conditions early
• Care must be taken when handling the air intake replacement will be required 20,000 kms. In
system components. Components should not be case Air filter element is not replaced on time,
lifted by using their hoses or pipes. vehicle's performance gets affected.
• Hoses and lines must not be subjected to any
twists or stress.
• Ensure that hoses are positioned in their correct
run before tightening the couplings, and ensure CAUTION
that all clips and supports are used.
Before starting work on the engine always
• To achieve an optimum cooling of the com-
pressed air it is vital that the vehicle’s number switch off the engine and disconnect the HFM
plate position is not changed and/ or an oversize connection.
number plate does not block the aperture for the
air draft for the intercooler.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-4 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Incar Repairs Air Cleaner Duct - Dirty Side

It should be noted that if the engine run with a
clogged air filter element, then it will lead to the seep-
age of oil from the turbocharger into the air intake
system.

Notice
Ensure that only the recommended engine oil
is used and the specified drain intervals are
maintained.

Check for oil leaks in the air intake system and if

traces are found check the oil separator system.

Removal
1. Remove the battery. For additional
information refer to Battery removal and
installation section.
2. Remove the fuse box. For additional informa-
tion refer to Fuse Box removal and installa-
tion section.
3. Remove the front bumper assembly. For addi-
tional information refer to Front Bumper
removal and installation section.
4. Remove the LHS headlamp Assembly. For
additional information refer to Headlamp
removal and installation section.
5. Remove the 10mm mounting bolt and two nuts
(A) from the bottom cover of the fuse box.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-5
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

6. Remove the 10mm mounting clamp bolt (A) of Air Filter Element
the air cleaner duct.

Removal
7. Remove the air cleaner duct hose (A) from the
air cleaner assembly and detach the air cleaner 1. Remove the negative terminal of the battery. For
duct. additional information refer to Battery
removal and installation section.

Notice
The air cleaner element should be replaced
every 40,000 kms under normal driving
[Link] extremely dusty conditions
replace at 20,000 kms.

A Notice
It should be noted that if the engine is run
with clogged air cleaner, then it will lead to
seepage of oil from turbocharger into the air
intake system.

Installation 2. Press the lock and pull out the electrical

connector (A) of the HFM sensor.
CAUTION
Care should be taken while installing the fuse
box. Damage in the fuse box connectors and
fuses may cause short circuit or starting
problem in the vehicle.

1. To install, reverse the removal procedure.

Notice A
Install the air cleaner duct properly with the
air cleaner to avoid the air noise from the
engine compartment.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-6 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

3. Loosen the air cleaner outlet hose clamp (A) 6. Remove the air cleaner top cover (A) separately.
from the air cleaner.

7. Remove the air filter element (A) from the air

4. Disconnect the tags (A) from both sides of the air cleaner bottom cover.
cleaner.

5. Using a 5mm allen key remove the seven air Installation

cleaner top cover mounting bolts (A). 1. To install, reverse the removal procedure.

Notice
Clean the air cleaner bottom cover before
installing the air filter [Link] not over
tight the air cleaner mounting bolts, over
tightened will lead to damage of housing
threads.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-7
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Air Filter Housing 4. Press the lock and disconnect the electrical con-
nector (A) of the fuel temperature sensor.

Removal
5. Loosen the 13mm mounting bolt (A) of the air
1. Remove the negative terminal of the battery. For cleaner assembly and detach the air filter hous-
additional information refer to Battery ing assembly.
removal and installation section.
2. Press the lock and pull out the electrical connec- Notice
tor (A) of the HFM sensor.
Carefully remove the air cleaner assembly, to
avoid the damage of air cleaner mountings.

3. Loosen the air filter outlet hose clamp (A) from

the air filter housing.

Installation
1. To install, reverse the removal procedure.

Notice
Install the air cleaner properly with the air
A cleaner duct to avoid the air noise from the
engine compartment.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-8 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Air Cleaner Outlet Hose - Clean 3. Unclip and remove the oil separator hose (A)
from the air outlet hose.
Side

4. Loosen the air cleaner outlet hose clamp (A)

Removal and remove the outlet hose (B) from the turbo
charger.
1. Remove the negative terminal of the battery. For
additional information refer to Battery
removal and installation section.
2. Unclip the vacuum modulator hose clip (A) and
remove the vacuum modulator hose (B) from the A
air outlet hose. B

B
Installation
1. To install, reverse the removal procedure.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-9
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Oil Separator 2. Remove the two 12mm oil separator heat shield
mounting bolts (A), and detach the shield from
the oil separator.

The oil separator separates oil from the blow by of

the engine and sends it back to engine oil sump.
The remaining air and other gases are sent to the 3. Unclip the clip (A) and remove the oil separator
inlet manifold. hose (B) from the oil separator unit.
There is also a spring loaded diaphragm valve
provided on the oil separator outlet to the inlet
manifold. This prevents the flow of excessive of
blow by from the oil separator to the inlet manifold
in case the air filter is chocked and high suction
starts acting on outlet port of oil separator.
No leakage past diaphragm or top cover of oil
separator is permitted. Replace the assembly if
B
there is any leakage or found defective.

Removal
1. Remove the negative terminal of the battery. For
additional information refer to Battery
removal and installation section. A

Notice 4. Detach the oil separator hose (A) from the clip
(B).
Check oil separator system, in particular for
any leak.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-10 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

5. Remove the six 10mm oil separator bolts (A), Oil Separator Hose
and detach the oil separator from the engine.

Removal
1. Remove the negative terminal of the battery. For
A additional information refer to Battery
removal and installation section.

Notice
Check oil separator system, in particular for
any leak.

2. Unclip and remove the oil separator hose (A)

from the air outlet hose.

Installation
1. To install, reverse the removal procedure.

Notice
Before installing the oil separator into the en-
gine, clean the oil separator and apply rec-
ommended sealant in the oil separator.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-11
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

3. Detach the oil separator hose (A) from the clip HFM Sensor
(B).

4. Unclip the clip (A) and remove the oil separator HFM Sensor is mounted between air filter and
hose (B) from the oil separator unit. turbocharger. This sensor gives Information about
the amount of air quantity and temperature of the
air entering in the engine. This input is used by the
ECU for corrections of fuel quantity based on
amount of air availability for optimization of exhaust
gas circulation & the turbocharger control.

Removal
1. Remove the negative terminal of the battery. For
additional information refer to Battery
B removal and installation section.
1. Remove the air cleaner top cover. For addi-
tional information refer to Air Filter Element
removal and installation section.
2. Using a 5mm Allen key Loosen the two HFM
A sensor mounting bolts (A) and remove the
HFM sensor from the air cleaner top cover.
Installation
1. To install, reverse the removal procedure. Notice
Handle the HFM Sensor carefully while re-
Notice moving to avoid damage.
Before installing the oil separator hose in-
spect for any damaged. Any vacuum leak will
lead to a high-pressure build up and then it
will go through the intake system. A

Notice
High-pressure build up in the intake system
give a signal of high blow by or be confused
with compressor oil leak.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-12 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Installation Boost Pressure Sensor

1. To install, reverse the removal procedure.

Notice
Do not over tighten the HFM mounting
[Link] tightening will lead to damage the
air cleaner mounting threads.

Notice
While installing, the HMF sensor the point of
the arrow should be towards the Turbo
charger at the time of installation.

Boost Pressure Sensor is fitted on intercooler outlet

near the pipe connecting intercooler to engine
intake. Measures the boost pressure for VGT
calibration.

Removal
1. Remove the negative terminal of the battery. For
additional information refer to Battery
removal and installation section.
2. Remove the engine NVH cover. For additional
information refer to NVH Cover removal and
installation section.
3. Press the lock and disconnect the electrical
connector of the boot pressure sensor (A) from
the inter cooler.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-13
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

4. Remove the 10mm boost pressure sensor NVH Cover

mounting bolt (A) and detach the boost
pressure sensor from the inter cooler.

Removal
Installation 1. Lift and detach the NVH cover at back side
1. To install, reverse the removal procedure. (A), slide and remove the NVH cover (B)
towards windscreen.
Notice
Inspect the boost pressure sensor 'o' ring
and boost pressure sensor for damaged.
A
A

Installation
1. Insert the NVH cover (A) into the bulk head (B)
and fix the NVH cover into the intercooler.

A
B

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-14 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Intercooler 4. Press the lock and disconnect the electrical

connector of the boot pressure sensor (A) from
the inter cooler.

The intercooler is a heat exchanger used to cool

the compressed hot air coming from the VGT 5. Loosen the inter cooler hose clip (A) and
(turbocharger) before it enters the intake manifold. remove the hose (B) from other side of the
It increased the density of the air and avoids the inter cooler.
chance of pre-ignition due to high intake air
temperature.

Removal B
1. Remove the negative terminal of the battery.
For additional information refer to Battery
removal and installation section.
2. Remove the engine NVH cover. For additional A
information refer to NVH Cover removal and
installation section.

Notice
Do not place any tool or parts over the
intercooler as it will damage the fins which
will lead reduced performance of intercooler.
6. Uncap the HFM sensor wiring harness clip (A)
from the inter cooler mounting bracket.
3. Loosen the inter cooler inlet hose clip (A) and
remove the hose (B) from the inter cooler.

B A

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-15
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

7. Remove the two 10mm inter cooler bracket Intercooler Inlet Hose
mounting bolts (A) from the fire wall side.

8. Remove the two 10mm inter cooler bracket Removal

mounting bolts (A) from the bulk head side and 1. Loosen the intercooler inlet hose clip (A) con-
detach the inter cooler assembly. nected to the inter cooler and remove the inlet
hose from the inter cooler.

A
A

Installation
2. Loosen the intercooler inlet hose clip (A)
1. To install, reverse the removal procedure. connected to the turbo charger and remove the
intercooler inlet hose (B) from the turbo
charger.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-16 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Installation Intercooler Outlet Hose

1. To install, reverse the removal procedure.

Notice
Inspect the intercooler inlet hose for any dam-
age. Install the intercooler inlet hose properly
to avoid the poor engine performance.

Removal
1. Loosen the intercooler outlet hose clip (A) con-
nected to the intake manifold and remove the
intercooler outlet hose (B) from the intake mani-
fold.

2. Loosen the intercooler outlet hose clip (A)

connected to the intercooler and remove the
outlet hose (B) from the inter cooler.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-17
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Installation Intercooler Bracket

1. To install, reverse the removal procedure.

Notice
Inspect the intercooler outlet hose for any
damage. Install the intercooler outlet hose
properly to avoid the poor engine
performance.

Removal
1. Remove the inter cooler assembly. For addi-
tional information refer to Intercooler
removal and installation section.
2. Remove the boost pressure sensor. For addi-
tional information refer to Boost Pressure
Sensor removal and installation section.
3. Remove the four 10mm mounting bracket bolts
(A) and detach the bracket from the inter
cooler.

Installation
1. To install, reverse the removal procedure.

Notice
Before installing the inter cooler, check the
inter cooler mounting bracket rubbers
condition to avoid rattling noise from the
engine compartment.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-18 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Diagnostics and Testing

Troubleshooting Chart

Symptom Possible Causes Remedy

1. Air intake obstructed. 1. Check the service indicator light

Engine does not [Link] air filter element if ex-
start & emits black treme dirt.
smoke 2. Check for free operation of turbo-
charger.

1. Air intake restricted. 1. Replace the air filter element.

2. Air leaks in system after turbocharger. 2. Plug the leaks, replace hose or clip if
required.
3. Air leaks in pipe manifold to FIP. 3. Replace the hose or tighten.
Engine does not
give full power 4. Boost pressure control valve stuck in 4. Correct the control valve and find
open condition. the cause.

5. Boost pressure pipe/hose assembly 5. Check the pipe, washer and rectify.
damaged.

6. Turbocharger damaged. 6. Replace the turbocharger.

1. Air intake restricted. 1. Check the hoses, replace the air fil-
ter element.
2. Air leaks between the turbocharger and 2. Check for leaks between the turbo-
Black smoke inlet manifold. charger and the intercooler and be-
tween the intercooler and the inlet
manifold. Remove the restriction or
replace them if necessary.

1. A clogged air filter element. 1. Clean or replace the air filter ele-
ment.
2. Obstruction in the crankcase breather. 2. Locate and remove the restriction in
crankcase breather.

3. Obstruction in air intake of the turbo- 3. Check the crankcase and replace it
charger compressor. if necessary.
4. Leaks in the inlet manifold mounting 4. Change the manifold gasket or re-
face which allows the entry of dust par- place the manifold.
Excess oil con-
ticles.
sumption
5. Air leakage between the turbocharger 5. Locate the leaks, change the hose
and intake manifold. or clamp if required.
6. Thick oil/sludge or coke in the turbo 6. Change oil, filter, service the turbo
chargers central housing. charger and use recommended oils
and drain [Link] the recom-
mended procedure while shutting
down.
7. Turbo charger damaged. 7. Replace the turbo charger.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-19
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Symptom Possible Causes Remedy

1. Clogged air filter element. 1. Clean or replace the air filter ele-
ment.
Black smoke
2. Air leakage between the turbocharger 2. Locate the leaks, and change the
and the intake manifold. hose or clamp if required.

1. Air intake is obstructed. 1. Clean the air filter, replace if re-

quired.
2. Air leak in pressure line after turbo 2. Plug the leaks and replace the hose
Engine underpow- charger (Turbo to intercooler and inter- or clip if required.
ered cooler to manifold).

3. The pressure booster pipe/hose as- 3. Check the pipe or washer of the
sembly is damaged. pressure booster pipe and replace it
if necessary.

1. Indication of air leakage between the 1. Tighten the clamps at the intercool-
turbocharger to inlet manifold. er and the turbocharger inlet and
outlet.
Whining noise
clearly audible after 2. Check the hoses for leakage and
2000 RPM and replace the hoses if necessary.

3. Check and replace the inlet and

outlet pipe of the intercooler.

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
3-20 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured.
 MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2

Component Inspection and Action Table

Component Inspection Action

Air filter 1. Inspect the air filter element for possible damage. 1. Replace the element.

2. Inspect the air filter element for clogging. 2. Clean the element and re-
place if required.

1. Inspect air intake manifold for cracks or distortion. 1. Replace if cracks or dam-
ages are found.

Air intake mani- 2. Check for air leakage between block and intake mani- 2. Check surface for distor-
fold and hoses fold. tion.

1. Check for fins distortion, damage. 1. Replace the intercooler.

Intercooler 2. Check for blockage.
2. Replace the intercooler.

Technical Specification
Description Specification

Air Filter Type Foam

Air Filter Volume 11 liters

Service Interval 40,000 km

Torque Specification
Torque in
Part Bolt Specification Place of Application Quantity
Nm

COMBI SCREW
ALLEN TYPE HFMS to air cleaner 2 2.5±0.5
M6X1X18

SCREW HEX FL
Oil separator hose mounting to engine 1 8.0~10.0
Air cleaner and at- M6X1X15X8.8XGR
tachment
BOLT HEX FL
M8X1.25X30X8.8X Air cleaner to BIW 1 12.0±0.5
ZN

SCREW HEX FL
Dirty side mounting to bolster 1 8.0~10.0
M6X1X15X8.8XGR

HOSE CLIP W
Inlet and outlet hose mounting 4 6.0~8.0
M65X0.9X12XSS

SCREW HEX FL Boost pressure sensor mounting to in-

Intercooler 1 3.5±0.5
M6X115X8.8XGR ter cooler

BOLT HEX FL Inter-cooler craddle to BIW and Front

4 6.0±1.5
M6X1X25X8.8XZN end carrier

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The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 3-21
component units and accessories from which the vehicles are manufactured.