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

id0113f3801900

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.	(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.	—
6	Switch the ignition to on (Engine off).	—
7	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
8	Switch the ignition to off.	—
9	Wait for 20 s.	—
10	Start the engine.	—
11	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].)
12	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.	—
4	Switch the ignition to on (Engine off).	—
5	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
6	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].)
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.	—

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

am6zzw00004116

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

Step 2

am6zzw00004117

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.) (See Water Hose Installation Note.)
8	Intake shutter valve
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	VBC check valve
17	Vacuum damper
18	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

Warning

•  Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.

•  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.

Caution

•  Do not plug the water hose with a sharp-edged object. Otherwise, the hose could be damaged.

Intake manifold not removed

Note

•  If the intake manifold is not removed at the same time (if only intake shutter valve is removed), remove the intake shutter valve without draining the engine coolant.

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

Note

•  If the intake manifold is removed at the same time, drain the engine coolant and remove the intake shutter valve.

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.

•  Fuel injector connector

•  Boost sensor connector

•  Fuel pressure sensor connector

•  EGR cooler bypass valve control solenoid valve connector

•  Front harness-short cord connector

am6zzw00004274

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.

am6zzw00007597

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.

am6zzw00004480

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.

am6zzw00004119

Caution

•  If the O-ring is pinched when installing the charge air cooler air inlet or outlet pipe to the charge air cooler, airtightness cannot be ensured and the charge air cooler air inlet or outlet pipe could be damaged. Therefore, install the pipe so that the O-ring is not pinched

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.

•  If there is a space, it indicates a possibility that the O-ring may be pinched. Replace the O-ring with a new one and repeat the procedure from the beginning.

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.

am6zzw00004481