INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2]

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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 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 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.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

Step 1

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1
MAF/IAT sensor connector
2
MAF/IAT sensor
3
Air inlet hose
4
Fresh-air duct No.1
5
Fresh-air duct No.2
6
Fresh-air duct No.3
7
Air cleaner cover
8
Air cleaner element
9
Air cleaner case
10
Air inlet pipe
11
Turbocharger air outlet hose
(See Clamp Installation Note.)
12
Turbocharger air outlet pipe No.2 bracket
13
Turbocharger air outlet pipe No.2
14
Charge air cooler air inlet hose
(See Charge Air Cooler Air Inlet Hose Removal Note.)
(See Clamp Installation Note.)
15
Charge air cooler air outlet hose
(See Clamp Installation Note.)
16
Charge air cooler air outlet pipe bracket No.1
17
Charge air cooler air outlet pipe
(See Charge Air Cooler Air Outlet Pipe Removal Note.)
18
Charge air cooler bracket No.1
19
Charge air cooler bracket No.2
20
Charge air cooler cover
21
Charge air cooler duct
(See Charge Air Cooler Duct Removal Note.)
22
IAT sensor No.2
23
Charge air cooler

Step 2

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1
Turbocharger air inlet pipe bracket
(See Turbocharger Air Inlet Pipe Bracket, Turbocharger Air Inlet Pipe, Turbocharger Air Outlet Pipe No.1 Installation Note.)
2
Rubber
3
Spacer
4
Ventilation hose
5
Turbocharger air inlet pipe
(See Turbocharger Air Inlet Pipe Bracket, Turbocharger Air Inlet Pipe, Turbocharger Air Outlet Pipe No.1 Installation Note.)
6
Turbocharger air outlet pipe No.1
(See Turbocharger Air Inlet Pipe Bracket, Turbocharger Air Inlet Pipe, Turbocharger Air Outlet Pipe No.1 Installation Note.)
7
Water hose
(See Water Hose Removal Note.)
8
Intake shutter valve
(See Intake Shutter Valve Removal Note.)
9
Air intake elbow
(See Air Intake Elbow Removal Note.)
10
EGR cooler bypass valve control solenoid valve connector
(See EGR Cooler Bypass Valve Control Solenoid Valve Bracket No.1 Removal Note.)
11
EGR cooler bypass valve control solenoid valve bracket No.1
12
EGR cooler bypass valve control solenoid valve bracket No.2
13
EGR cooler bypass valve control solenoid valve
14
Intake manifold
(See Intake Manifold Removal Note.)
(See Intake Manifold Installation Note.)
15
VBC solenoid valve
16
Vacuum damper
17
VBC check valve
18
Vacuum chamber


Charge Air Cooler Air Inlet Hose Removal Note

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

2.  Remove the charge air cooler air inlet hose.


Charge Air Cooler Air Outlet Pipe Removal Note

1.  Set the front mudguard (LH) out of the way. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

2.  Remove the charge air cooler air outlet pipe.


Charge Air Cooler Duct Removal Note

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

2.  Remove the charge air cooler duct.


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.


Water Hose Removal Note

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

2.  Disconnect the water hose.


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.  Set the generator out of the way. (See GENERATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

10.  Loosen the bypass pipe installation bolts.

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11.  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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Turbocharger Air Inlet Pipe Bracket, Turbocharger Air Inlet Pipe, Turbocharger Air Outlet Pipe No.1 Installation Note

1.  Temporary tighten in the order shown in the figure.

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2.  Tighten the nut A.

3.  Tighten the nut B.

4.  Tighten the bolt C.

5.  Tighten the bolt D.

6.  Tighten the bolt E.


Clamp Installation Note

Note
•  Whenever engine oil adheres to the hose and pipe, it wipes off.

1.  Install the clamp as shown in the figure.

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