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

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EURO4 Emission Level

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”. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [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) (EURO4 emission level)].)

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 cooler. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

8.  Remove the fuel pipe bracket. (See FUEL INJECTOR 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
MAF/IAT sensor
2
Air hose
3
Air cleaner bracket
4
Fresh-air duct No.1
5
Fresh-air duct No.2
6
Air cleaner
7
Air pipe
8
Charge air cooler inlet hose
9
Charge air cooler outlet hose
10
Charge air cooler
(See Charge air cooler removal note.)
11
EGR throttle valve component
12
Intake manifold


Charge air cooler removal note

1.  Remove the charge air cooler fan from the charge air cooler.

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2.  Remove the charge air cooler.


EURO5 Emission Level

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.
Note
•  If the intake shutter valve is replaced, complete the “INTAKE AIR THROTTLE VALVE LEARNED VALUES RESET”. (See INTAKE AIR THROTTLE VALVE LEARNED VALUES RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].)
•  If the MAF/IAT sensor is replaced, complete the “MASS AIR FLOW SENSOR LEARNED VALUES RESET”. (See MASS AIR FLOW SENSOR LEARNED VALUES RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

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

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

3.  Disconnect the wiring harness.

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

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1
Fresh-air duct No.1
2
Fresh-air duct No.2
3
Air cleaner bracket
4
Air cleaner
5
Air hose No.1
6
Ventilation hose
7
Air hose No.2
8
Charge air cooler inlet hose
(See Charge air cooler inlet hose Installation Note.)
9
Charge air cooler outlet hose
(See Charge air cooler outlet hose Installation Note.)
10
Charge air cooler bracket
11
Intake air pipe No.1
12
Intake air pipe No.2
13
Intake shutter valve
14
Intake air pipe No.3
15
Charge air cooler
16
Intake air pipe No.4


Charge air cooler outlet hose Installation Note

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

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Charge air cooler inlet hose Installation Note

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

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