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

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

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 Removal Note.) (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
9	Air intake elbow (See Air Intake Elbow Removal Note.)
10	EGR cooler bypass valve control solenoid valve bracket No.1 (See EGR Cooler Bypass Valve Control Solenoid Valve Bracket No.1 Removal Note.)
11	EGR cooler bypass valve control solenoid valve bracket No.2
12	EGR cooler bypass valve control solenoid valve
13	Intake manifold (See Intake Manifold Removal Note.) (See Intake Manifold Installation Note.)
14	VBC solenoid valve
15	VBC check valve
16	Vacuum damper
17	Vacuum chamber