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”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)
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.
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.
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.
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.
5
Perform intake shutter valve/EGR valve initialization procedure.
Engine coolant temperature 60—95 °C {140—203 °F}.
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.
10
Switch the ignition to off.

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Disconnect the wiring harness.

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
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
10
Turbocharger air outlet pipe No.2 bracket
11
Turbocharger air outlet pipe No.2
12
Charge air cooler air inlet hose
13
Charge air cooler air outlet hose
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
18
Charge air cooler air outlet pipe bracket No.1
19
Charge air cooler air outlet pipe
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
24
Charge air cooler bracket No.2
25
Charge air cooler

Step 2

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1
Turbocharger air inlet pipe bracket
2
Rubber
3
Spacer
4
Ventilation hose
5
Turbocharger air inlet pipe
6
Turbocharger air outlet pipe No.1
7
Water hose
8
Intake shutter valve
9
Air intake elbow
10
EGR cooler bypass valve control solenoid valve bracket No.1
11
EGR cooler bypass valve control solenoid valve bracket No.2
12
EGR cooler bypass valve control solenoid valve
13
Intake manifold
14
VBC solenoid valve
15
VBC check valve
16
Vacuum damper
17
Vacuum chamber


Turbocharger Air Outlet Pipe No.2 Removal Note

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

2.  Remove the turbocharger air outlet pipe No.2.


Charge Air Cooler Air Inlet 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 inlet pipe.


Charge Air Cooler Duct Removal Note

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

2.  Remove the charge air cooler duct.


Turbocharger Air Inlet Pipe Removal Note

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

2.  Remove the turbocharger air inlet pipe.


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 COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Remove the EGR pipe. (See EGR VALVE REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  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. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.  Remove the common rail. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

6.  Remove the glow cord. (See GLOW PLUG REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.  Remove the glow plug. (See GLOW PLUG REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.  Disconnect the water hose. (See RADIATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove the water outlet case. (See RADIATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

10.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

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.

Tightening torque
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

3.  Tighten the nut B.

Tightening torque
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

4.  Tighten the bolt C.

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

5.  Tighten the bolt D.

Tightening torque
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

6.  Tighten the bolt E.

Tightening torque
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}


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

1.  Install a new O-ring to the charge air cooler.

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

3.  Tighten in the order shown in the figure.

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


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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