INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)]

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Предупреждение

• A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake air system.

• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See МЕРЫ ПРЕДОСТОРОЖНОСТИ ПЕРЕД ПРОВЕДЕНИЕМ РЕМОНТА [MZ-CD 1.6 (Y6)].)

2. Disconnect the negative battery cable.

3. Remove the engine cover.

4. Remove the EGR valve, EGR water cooler and pipe when removing the intake manifold. (See СНЯТИЕ И УСТАНОВКА КЛАПАНА EGR [MZ-CD 1.6 (Y6)].)

6. Remove in the order indicated in the table.

7. Install in the reverse order of removal.

8. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See AFTER REPAIR PROCEDURE [MZ-CD 1.6 (Y6)].)

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1

Air hose

(See Clamp Installation Note.)

2

Combined MAF sensor and IAT sensor

3

Air cleaner

(See Air Cleaner Installation Note.)

4

Ventilation hose

5

Air pipe

6

Turbocharger

(See СНЯТИЕ И УСТАНОВКА ВЫПУСКНОЙ СИСТЕМЫ [MZ-CD 1.6 (Y6)].)

7

Upper cylinder head cover

(See Upper Cylinder Head Cover Installation Note.)

8

Air by pass valve (High power-Euro 4)

9

Air hose (air pipe (intake throttle valve component) (Standard power-Euro 4))

10

Charge air cooler pipe and hose

(See Clamp Installation Note.)

11

Charge air cooler

(See Charge Air Cooler/Resonance Chamber Removal Note.)

12

Resonance chamber

(See Charge Air Cooler/Resonance Chamber Removal Note.)

(See Resonance Chamber Installation Note.)

13

Intake manifold

(See Intake Manifold Installation Note.)

Charge Air Cooler/Resonance Chamber Removal Note

1. Remove the front bumper when removing the charge air cooler and/or resonance chamber. (See СНЯТИЕ И УСТАНОВКА ПЕРЕДНЕГО БАМПЕРА.)

2. Remove the PCM when removing the resonance chamber. (See PCM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

Intake Manifold Installation Note

1. Temporarily tighten the bolts then tighten the bolts when instal the upper cylinder head cover. (See Upper Cylinder Head Cover Installation Note.)

Resonance Chamber Installation Note

1. Temporarily tighten bolt A, then tighten in the order of B, A and C.

Tightening torque

7.9—11.7 N·m {80.6—119.3 kgf·cm, 70.0—103.5 in·lbf}

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Clamp Installation Note

1. Install the clamp as shown in the figure.

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2. Tighten the charge air cooler pipe installation bolt and nut in the order shown in the figure.

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Upper Cylinder Head Cover Installation Note

Примечание

• Install the upper cylinder head cover and the intake manifold retaining bolts in the sequence shown.

1. Tighten the intake manifold and upper cylinder head cover installation bolts in the following steps.

(1) Temporarily tighten the bolts.

(2) Tighten the bolts in the order shown in the figure.

Tightening torque

8.9—12.1 N·m {90.8—123.3 kgf·cm, 78.8—107.0 in·lbf}

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Air Cleaner Installation Note

1. Using the strap, secure the shroud panel and the mount rubber as shown in the figure.

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1	Air hose (See Clamp Installation Note.)
2	Combined MAF sensor and IAT sensor
3	Air cleaner (See Air Cleaner Installation Note.)
4	Ventilation hose
5	Air pipe
6	Turbocharger (See СНЯТИЕ И УСТАНОВКА ВЫПУСКНОЙ СИСТЕМЫ [MZ-CD 1.6 (Y6)].)
7	Upper cylinder head cover (See Upper Cylinder Head Cover Installation Note.)
8	Air by pass valve (High power-Euro 4)
9	Air hose (air pipe (intake throttle valve component) (Standard power-Euro 4))
10	Charge air cooler pipe and hose (See Clamp Installation Note.)
11	Charge air cooler (See Charge Air Cooler/Resonance Chamber Removal Note.)
12	Resonance chamber (See Charge Air Cooler/Resonance Chamber Removal Note.) (See Resonance Chamber Installation Note.)
13	Intake manifold (See Intake Manifold Installation Note.)