INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]

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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”.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 2.0, MZR 2.5].)

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

4.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

5.  Disconnect the wiring harness.

6.  Remove in the order indicated in the table.

7.  Install in the reverse order of removal.

8.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5].)

Step 1

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1	MAF/IAT sensor
2	Ventilation hose
3	Air cleaner cover (See Air Cleaner Cover Removal Note.)
4	Resonance chamber
5	Air hose (See Air Hose Installation Note)
6	Air cleaner element
7	Air cleaner case
8	Fresh-air duct (No.1) (See Fresh-Air Duct (No.1) Removal Note)
9	Fresh-air duct (No.2)
10	Fresh-air duct (No.3)

Step 2

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1	Water hose (SeeWater Hose Removal Note.)
2	Throttle body (See Throttle Body Installation Note.)
3	Vacuum hose
4	Variable intake air solenoid valve
5	Vacuum hose
6	Variable tumble solenoid valve
7	Vacuum hose
8	Quick release connector (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
9	Vacuum cap (MZR 2.5)
10	Intake manifold (See Intake Manifold Removal Note.)

Air Cleaner Cover Removal Note

1.  Remove the air cleaner cover and resonance chamber and air hose a as single unit.

2.  Remove the air cleaner cover.

Fresh-Air Duct (No.1) Removal Note

1.  Remove the fresh-air duct (No.1) and fresh-air duct (No.2) a as single unit.

2.  Remove the fresh-air duct (No.1).

Water Hose Removal Note

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 2.0, MZR 2.5].)

2.  Disconnect the water hose.

Intake Manifold Removal Note

1.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

2.  Remove all clips for securing wiring harnesses from the intake manifold.

3.  Disconnect the vacuum hoses connecting the intake manifold.

4.  Remove the fuel distributor and fuel injector a as single unit. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

5.  Remove the intake manifold.

Throttle Body Installation Note

1.  Tighten the installation bolts in the order shown in the figure.

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Air Hose Installation Note

1.  Adjust the convex of the throttle body to the recess of the air hose.

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