INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2]
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MAF sensor
STEP |
ACTION |
PAGE/CONDITION |
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1
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Replace the MAF/IAT sensor.
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—
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2
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Switch the ignition to on.
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—
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3
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Perform mass air flow (MAF) sensor data reset procedure.
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4
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Start the engine.
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Verify that the MIL dose not illuminate.
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5
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Switch the ignition to off.
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—
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6
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Switch the ignition to on (Engine off).
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—
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7
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Perform KOEO self-test procedure.
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8
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Switch the ignition to off.
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—
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9
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Wait for 20 s.
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—
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10
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Start the engine.
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—
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11
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Perform KOER self-test procedure.
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Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2 PID) is 100 °C {212 °F} or more.
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12
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Switch the ignition to off.
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—
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Intake shutter valve
STEP |
ACTION |
PAGE/CONDITION |
---|---|---|
1
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Replace the intake shutter valve.
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—
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2
|
Start the engine.
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Verify that the MIL dose not illuminate.
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3
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Switch the ignition to off.
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—
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4
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Switch the ignition to on (Engine off).
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—
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5
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Perform KOEO self-test procedure.
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6
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Perform intake shutter valve/EGR valve initialization procedure.
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Engine coolant temperature 60—95 °C {140—203 °F}.
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7
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Switch the ignition to off.
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—
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8
|
Wait for 20 s.
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—
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9
|
Start the engine.
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—
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10
|
Perform KOER self-test procedure.
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Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2 PID) is 100 °C {212 °F} or more.
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11
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Switch the ignition to off.
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—
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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. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing. (Intake manifold not removed)
6. Refill the engine coolant. (Intake manifold removed)
7. Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [MZR-CD 2.2].)
8. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR-CD 2.2].)
Step 1
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1
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MAF/IAT sensor connector
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2
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MAF/IAT sensor
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3
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Air inlet hose No.1
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4
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Air inlet hose No.2
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5
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Air cleaner cover
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6
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Air cleaner element
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7
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Air cleaner case
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8
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Air cleaner bracket
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9
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Air inlet pipe
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10
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Turbocharger air outlet hose
(See Clamp Installation Note.)
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11
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Turbocharger air outlet pipe No.2 bracket
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12
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Turbocharger air outlet pipe No.2
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13
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Charge air cooler air inlet hose
(See Clamp Installation Note.)
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14
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Charge air cooler air outlet hose
(See Clamp Installation Note.)
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15
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Charge air cooler air inlet pipe
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16
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Charge air cooler air outlet pipe bracket No.1
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17
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Charge air cooler air outlet pipe
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18
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Charge air cooler air outlet pipe bracket No.2
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19
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IAT sensor No.2
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20
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Charge air cooler bracket No.1
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21
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Charge air cooler duct
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22
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Charge air cooler bracket No.2
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23
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Charge air cooler
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Step 2
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1
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Turbocharger air inlet pipe bracket
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2
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Rubber
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3
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Spacer
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4
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Ventilation hose
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5
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Turbocharger air inlet pipe
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6
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Turbocharger air outlet pipe No.1
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7
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Water hose
(See Water Hose Removal Note.)
(See Water Hose Installation Note.)
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8
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Intake shutter valve
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9
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Air intake elbow
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10
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EGR cooler bypass valve control solenoid valve connector
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11
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EGR cooler bypass valve control solenoid valve bracket No.1
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12
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EGR cooler bypass valve control solenoid valve bracket No.2
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13
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EGR cooler bypass valve control solenoid valve
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14
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Intake manifold
(See Intake Manifold Removal Note.)
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15
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VBC solenoid valve
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16
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VBC check valve
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17
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Vacuum damper
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18
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Vacuum chamber
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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
Intake manifold not removed
1. Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.
2. Remove the water hose from the intake shutter valve and plug the water hose quickly.
Intake manifold removed
1. Drain the engine coolant before disconnect the water hose. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)
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.
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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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Water Hose Installation Note
1. Remove the plug from the engine coolant hose and install the water hose to the intake shutter valve quickly. (Intake manifold not removed)
2. Install the water hose to the intake shutter valve. (Intake manifold removed)
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.
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.
2. Apply grease (RFY1 13569) along the perimeter of the installed O-ring.
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3. Install the charge air cooler air inlet or outlet pipe to the charge air cooler.
4. Verify that the charge air cooler air inlet or outlet pipe is installed to the charge air cooler with no space between the two.
Clamp Installation Note
1. Install the clamp as shown in the figure.
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