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Warning

• When the engine and intake-air system are hot, they can cause severe burns or injury. Turn off the engine and wait until they are cool before removing or installing the intake-air system.

• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage, Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel Line Safety Procedure”.

Note

• If the MAF sensor or intake shutter valve, or both are replaced, always perform each adjustment procedure using the following steps.

MAF sensor

STEP	ACTION	PAGE/CONDITION
1	Replace the MAF/IAT sensor.	—
2	Switch the ignition to on.	—
3	Perform mass air flow (MAF) sensor data reset procedure.	(See MASS AIR FLOW (MAF) SENSOR DATA RESET [MZR-CD 2.2].)
4	Start the engine.	Verify that the MIL dose not illuminate.
5	Switch the ignition to off (Engine off).	—
6	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
7	Switch the ignition to off.	—
8	Wait for 20 s.	—
9	Start the engine.	—
10	Perform KOER self-test procedure.	Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2, EXHTEMP3 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)
11	Switch the ignition to off.	—

Intake shutter valve

STEP	ACTION	PAGE/CONDITION
1	Replace the intake shutter valve.	—
2	Start the engine.	Verify that the MIL dose not illuminate.
3	Switch the ignition to off (Engine off).	—
4	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
5	Perform intake shutter valve/EGR valve initialization procedure.	Engine coolant temperature 60—95 °C {140—203 °F}. (See INTAKE SHUTTER VALVE/EGR VALVE INITIALIZATION [MZR-CD 2.2].)
6	Switch the ignition to off.	—
7	Wait for 20 s.	—
8	Start the engine.	—
9	Perform KOER self-test procedure.	Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2, EXHTEMP3 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)
10	Switch the ignition to off.	—

1.Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

2.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.Disconnect the wiring harness.

5.Remove in the order indicated in the table.

6.Install in the reverse order of removal.

7.Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

8.Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing. (Intake manifold not removed)

9.Refill the engine coolant. (Intake manifold removed)

10.Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [MZR-CD 2.2].)

11.Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR-CD 2.2].)

Step 1

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Step 2

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Turbocharger Air Outlet Hose Removal Note

1.Remove the turbocharger air outlet hose and turbocharger air outlet pipe as a single unit.

2.Remove the turbocharger air outlet hose.

Charge Air Cooler Air Inlet Hose Removal Note

1.Remove the under cover.

2.Remove the charge air cooler air inlet hose.

Charge Air Cooler Air Inlet Pipe Removal Note

1.Set the front mudguard out of the way.

2.Remove the charge air cooler air inlet pipe.

Charge Air Cooler Duct Removal Note

1.Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION.)

2.Remove the charge air cooler duct.

Water Hose Removal Note

Warning

• 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.

Caution

• Do not plug the water hose with a sharp-edged object. Otherwise, the hose could be damaged.

Intake manifold not removed

Note

• If the intake manifold is not removed at the same time (if only intake shutter valve is removed), remove the intake shutter valve without draining the engine coolant.

1.Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.

2.Remove the water hose from the intake shutter valve and plug the water hose quickly.

Intake manifold removed

Note

• If the intake manifold is removed at the same time, drain the engine coolant and remove the intake shutter valve.

1.Drain the engine coolant before disconnect the water hose. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

Intake Shutter Valve Removal Note

1.Remove the EGR pipe. (See EGR VALVE REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.Remove the intake shutter valve.

Air Intake Elbow Removal Note

1.Set the fuel return pipe out of the way.

2.Remove the injection pipe (supply pump side). (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.Remove the air intake elbow.

EGR Cooler Bypass Valve Control Solenoid Valve Bracket No.1 Removal Note

1.Remove the EGR cooler bypass valve control solenoid valve bracket No.1, EGR cooler bypass valve control solenoid valve bracket No.2 and EGR cooler bypass valve control solenoid valve as a single unit.

2.Remove the EGR cooler bypass valve control solenoid valve bracket No.1.

Intake Manifold Removal Note

1.Disconnect the following parts and set the fuel injector wiring harness out of the way.

• Fuel injector connector

• Boost sensor connector

• Fuel pressure sensor connector

• EGR cooler bypass valve control solenoid valve connector

• Front harness-short cord connector

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2.Remove the injection pipe (fuel injector side). (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.Remove the dipstick pipe. (See CYLINDER HEAD GASKET REPLACEMENT [MZR-CD 2.2].)

4.Remove the boost sensor and the common rail. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.Remove the glow cord and the glow plug. (See GLOW PLUG REMOVAL/INSTALLATION [MZR-CD 2.2].)

6.Disconnect the water hose.

7.Remove the water outlet pipe.

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8.Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.Loosen the bypass pipe installation bolts.

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10.Remove the intake manifold.

Intake Manifold Installation Note

1.Tighten the intake manifold installation bolts and nuts in the order shown.

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Water Hose Installation Note

1.Remove the plug from the engine coolant hose and install the water hose to the intake shutter valve quickly. (Intake manifold not removed)

2.Install the water hose to the intake shutter valve. (Intake manifold removed)

Charge Air Cooler Air Outlet Pipe, Charge Air Cooler Air Inlet Pipe Installation Note

1.Install the O-ring shown in the figure.

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2.Install the charge air cooler air outlet or inlet pipe.

Charge Air Cooler Air Outlet Hose Installation Note

1.Install the charge air cooler air outlet hose shown in the figure.

Note

• Adhere the hose clamp 1—4 mm {0.04—0.15 in} from charge air cooler air outlet hose end.

• Adhere the hose clamp with hose clamp mark aligned with mark center.

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Charge Air Cooler Air Inlet Hose Installation Note

1.Install the charge air cooler air inlet hose shown in the figure.

Note

Turbocharger air outlet pipe side

• Mark on the charge air cooler air inlet hose must be overlapped with range of A.

• Hose clamp must be installed with mark in range of B.

Charge air cooler air inlet pipe side

• Hose clamp bolt must be locate in position of C.

• Adhere the hose clamp 1—4 mm {0.04—0.15 in} from charge air cooler air inlet hose end.

• Adhere the hose clamp with hose clamp mark aligned with charge air cooler air inlet hose mark center.

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Turbocharger Air Outlet Hose Installation Note

1.Install the turbocharger air outlet hose shown in the figure.

Note

• Mark on the turbocharger air outlet hose must be overlapped with range of A.

• Hose clamp must be installed with bolt center in range of B.

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Air Hose Installation Note

1.Install the air hose shown in the figure.

Note

• It installs it so that the top of match mark may come to range of the top of match mark.

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