INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)]

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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.

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

Note

•  If the intake shutter valve component is replaced, complete the “INTAKE SHUTTER VALVE ADAPTIVE VALUE RESET” and “EXHAUST GAS RELATED COMPONENT INITIALIZATION”.

(See INTAKE SHUTTER VALVE ADAPTIVE VALUE RESET [MZ-CD 1.6 (Y6)]].)

(See EXHAUST GAS RELATED COMPONENT INITIALIZATION [MZ-CD 1.6 (Y6)].)

•  If the Air hose and air cleaner component is replaced, complete the “EXHAUST GAS RELATED COMPONENT INITIALIZATION”.

(See EXHAUST GAS RELATED COMPONENT INITIALIZATION [MZ-CD 1.6 (Y6)].)

1.  Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

5.  Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

6.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

7.  Remove the EGR pipe. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

8.  Remove the fuel pipe bracket. (See FUEL FILTER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

9.  Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

10.  Disconnect the wiring harness.

11.  Remove in the order indicated in the table.

12.  Install in the reverse order of removal.

13.  Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

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1	Ventilation hose
2	Vacuum hose
3	Air hose and air cleaner component
4	Air pipe
5	Charge air cooler inlet hose
6	Charge air cooler outlet hose
7	Charge air cooler
8	Intake shutter valve component
9	Upper cylinder head cover (See Intake Manifold and Upper Cylinder Head Cover Installation Note.)
10	Intake manifold (See Intake Manifold and Upper Cylinder Head Cover Installation Note.)

Intake Manifold and Upper Cylinder Head Cover Installation Note

1.  Tighten the intake manifold and upper cylinder head cover bolts in the order show in the figure.

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