INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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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”. (See BEFORE SERVICE PRECAUTION [MZR-CD (RF Turbo)].)
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
Turn the engine switch on.
—
3
Perform mass air flow (MAF) sensor data reset procedure.
(See MASS AIR FLOW (MAF) SENSOR DATA RESET [MZR-CD (RF Turbo)].)
4
Start the engine.
Verify that the MIL dose not illuminate.
5
Turn the engine switch off.
—
6
Turn the engine switch on (Engine off).
—
7
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
8
Turn the engine switch off.
—
9
Wait for 20 s.
—
10
Start the engine.
—
11
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 (RF Turbo)].)
12
Turn the engine switch off.
—

Intake shutter valve

STEP

ACTION

PAGE/CONDITION
1
Replace the intake shutter valve.
—
2
Turn the engine switch on.
—
3
Perform intake shutter valve/EGR valve data reset procedure.
—
4
Start the engine.
Verify that the MIL dose not illuminate.
5
Switch the ignition to off.
—
6
Switch the ignition to on (Engine off).
—
7
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
8
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 (RF Turbo)].)
9
Switch the ignition to off.
—
10
Wait for 20 s.
—
11
Start the engine.
—
12
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 (RF Turbo)].)
13
Switch the ignition to off.
—

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2.  Remove the engine cover.

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

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

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

7.  Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [MZR-CD (RF Turbo)].)

8.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR-CD (RF Turbo)].)

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1
MAF/IAT sensor
2
Air cleaner cover
3
Air cleaner element
4
Air cleaner case
(See Air Cleaner Case Installation Note.)
5
Air inlet hose
6
Turbocharger air outlet pipe
(See Turbocharger Air Outlet Pipe Removal Note.)
7
Air inlet pipe
8
VBC solenoid valve
9
Vacuum pipe
10
VBC check valve
11
Turbocharger air outlet hose No.1
12
VBC vacuum damper
13
Charge air cooler air outlet hose
14
Turbocharger air outlet hose No.2
15
Charge air cooler duct
(See Charge Air Cooler Duct Removal Note.)
16
Charge air cooler
17
IAT sensor No.2
18
Charge air cooler inlet pipe
(See Charge Air Cooler Inlet Pipe, Charge Air Cooler Outlet Pipe Installation Note.)
19
Charge air cooler outlet pipe
(See Charge Air Cooler Inlet Pipe, Charge Air Cooler Outlet Pipe Installation Note.)
20
EGR pipe
(See EGR VALVE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
21
Intake shutter valve
(See Intake Shutter Valve Removal Note.)
(See Intake Shutter Valve Installation Note.)
22
Boost sensor
23
Intake manifold
(See Intake Manifold Removal Note.)
(See Intake Manifold Installation Note.)


Turbocharger Air Outlet Pipe Removal Note

1.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2.  Remove the air inlet pipe fitting bolts.

3.  Remove the turbocharger air outlet pipe.


Charge Air Cooler Duct Removal Note

1.  Remove the front bumper before removing the charge air cooler duct. (See FRONT BUMPER REMOVAL/INSTALLATION.)


Intake Shutter Valve 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.

3.  Remove the intake shutter valve.


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 (RF Turbo)].)

2.  Remove the intake shutter valve.


Intake Manifold Removal Note

1.  Remove the supply pump, common rail and injection pipe before removing the intake manifold. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)


Intake Manifold Installation Note

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

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2.  Install the supply pump, common rail and injection pipe. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)


Intake Shutter Valve Installation Note

1.  Install the intake shutter valve.

Tightening torque
7.8—10.8 N·m {80—110 kgf·cm, 70—95 in·lbf}

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

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


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

1.  Install a new O-ring to the charge air cooler inlet or outlet pipe.

2.  Apply grease (RFY1 13569) along the perimeter of the installed O-ring.

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Caution
•  If the O-ring is pinched when installing the charge air cooler inlet or outlet pipe to the charge air cooler, airtightness cannot be ensured and the charge air cooler inlet or outlet pipe could be damaged. Therefore, install the pipe so that the O-ring is not pinched

3.  Install the charge air cooler inlet or outlet pipe to the charge air cooler.

4.  Wipe away the excess grease.

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5.  Verify that the charge air cooler inlet or outlet pipe is installed to the charge air cooler with no space between the two.

•  If there is a space, it indicates a possibility that the O-ring may be pinched. Replace the O-ring with a new one and repeat the procedure from the beginning.


Air Cleaner Case Installation Note

Note
•  Before installing the air cleaner case, verify that the rubber mounts on the battery support bracket have not fallen off.
•  When inserting the air cleaner case into the rubber mounts, applying soapy water aids the operation.

1.  Verify that two rubber mounts are installed on the battery support bracket.

2.  Install the air cleaner case into the rubber mounts.

3.  Using the strap, secure the shroud panel and the air cleaner case as shown in the figure.

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