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INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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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 (RF Turbo)].)

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	Turn the engine switch on.	—
3	Perform mass air flow (MAF) sensor data reset procedure.	(See MASS AIR FLOW (MAF) SENSOR DATA RESET [MZR-CD (RF Turbo)].)
4	Start the engine.	Verify that the MIL dose not illuminate.
5	Turn the engine switch off.	—
6	Turn the engine switch on (Engine off).	—
7	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
8	Turn the engine switch 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, EXHTEMP3 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
12	Turn the engine switch off.	—

Intake shutter valve

STEP	ACTION	PAGE/CONDITION
1	Replace the intake shutter valve.	—
2	Turn the engine switch on.	—
3	Perform intake shutter valve/EGR valve data reset procedure.	—
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 (RF Turbo)].)
8	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 (RF Turbo)].)
9	Switch the ignition to off.	—
10	Wait for 20 s.	—
11	Start the engine.	—
12	Perform KOER self-test procedure.	Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2, EXHTEMP3 PID) is 100 °C {212 °F} or more. (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
13	Switch the ignition to off.	—

1.  Disconnect the negative battery cable.

2.  Remove the engine cover.

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 (RF Turbo)].)

8.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR-CD (RF Turbo)].)

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1	MAF/IAT sensor
2	Air inlet hose
3	Air cleaner cover
4	Air cleaner element
5	Air cleaner case (See Air Cleaner Case Installation Note.)
6	Air inlet pipe (See Air Inlet Pipe Removal Note.)
7	VBC solenoid valve
8	Vacuum pipe
9	VBC check valve
10	Turbocharger air outlet hose No.1
11	Turbocharger air outlet pipe
12	VBC vacuum damper
13	Charge air cooler air outlet hose
14	Turbocharger air outlet hose No.2
15	Charge air cooler duct
16	Charge air cooler (See Charge Air Cooler Removal Note.)
17	IAT sensor No.2
18	Charge air cooler inlet pipe
19	Charge air cooler outlet pipe
20	Intake shutter valve (See Intake Shutter Valve Removal Note.) (See Intake Shutter Valve Installation Note.)
21	Boost sensor
22	EGR pipe (See EGR VALVE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
23	Intake manifold (See Intake Manifold Removal Note.) (See Intake Manifold Installation Note.)

Air Inlet Pipe Removal Note

1.  Remove the battery and the battery tray before removing the air inlet pipe. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Charge Air Cooler Removal Note

1.  Remove the front bumper before removing the charge air cooler. (See FRONT BUMPER REMOVAL/INSTALLATION.)

Intake Shutter Valve 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.

3.  Remove the intake shutter valve.

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 (RF Turbo)].)

2.  Remove the intake shutter valve.

Intake Manifold Removal Note

1.  Remove the supply pump, common rail and injection pipe before removing the intake manifold. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2.  Remove the EGR valve before removing the intake manifold. (See EGR VALVE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Intake Manifold Installation Note

1.  Tighten the intake manifold installation bolts and nuts in the order shown.

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2.  Install the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

3.  Install the supply pump, common rail and injection pipe. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Intake Shutter Valve Installation Note

1.  Install the intake shutter valve.

2.  Remove the plug from the engine coolant hose and install the water hose to the intake shutter valve quickly. (Intake manifold not removed)

3.  Install the water hose to the intake shutter valve. (Intake manifold removed)

Air Cleaner Case Installation Note

Note

•  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.

•  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.