INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.8, 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 1.8, MZR 2.0, MZR 2.5].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

4.  Disconnect the wiring harness.

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 1.8, MZR 2.0, MZR 2.5].)

Step 1

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1	Air cleaner cover
2	Air cleaner element
3	Air cleaner case (See Air Cleaner Case Installation Note.)
4	Fresh-air duct
5	VAD solenoid valve (MZR 2.5)
6	Resonance chamber (See Resonance Chamber Removal Note.)
7	MAF/IAT sensor
8	Ventilation hose (air cleaner side) (See Ventilation Hose (Air Hose Side) Installation Note.)
9	Air hose (See Air Hose Removal Note.)
10	Air cleaner bracket

Step 2

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1	Throttle Body (See Throttle Body Removal Note.) (See Throttle Body Installation Note.)
2	Variable intake air solenoid valve (MZR 2.0, MZR 2.5)
3	Variable tumble solenoid valve
4	VAD check valve (MZR 2.5)
5	Intake manifold (See Intake Manifold Removal Note.)

Resonance Chamber Removal Note

1.  Remove the front mudguard (LH). (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

2.  Remove the resonance chamber.

Air Hose Removal Note

1.  Remove the purge solenoid valve bracket. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

2.  Remove the air hose.

Throttle Body Removal Note

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.8, MZR 2.0, MZR 2.5].)

2.  Disconnect the throttle body connector.

3.  Disconnect the water hose connecting the throttle body.

4.  Remove the throttle body.

Intake Manifold Removal Note

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

2.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

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

4.  Disconnect the vacuum hoses connecting the intake manifold.

5.  Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

6.  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 Cleaner Case Installation Note

Caution

•  Before assembling the air cleaner, verify that the rubber mounts have not fallen off from the air cleaner bracket (3 locations).

•  Always install the air cleaner case using the following procedure.

Note

•  When inserting the rubber mounts into the air cleaner case, soapy water can be applied.

1.  Verify that the rubber mounts are set in the air cleaner bracket (3 locations).

2.  Install the projections on the frame side (2 locations).

3.  Verify that the projections on the frame side are installed securely.

4.  Install the projection on the engine side (remaining location).

5.  Verify that the projection on the engine side installed securely.

Ventilation Hose (Air Hose Side) Installation Note

Note

•  Install the ventilation hose so that it passes over the brake vacuum hose.

1.  Connect the ventilation hose (air hose side).

2.  Verify that the ventilation hose connection area is inserted completely.