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

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Предупреждение

•  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 ПОДГОТОВКА К ПРОВЕДЕНИЮ РЕМОНТА [MZR-CD (RF Turbo)].)

Примечание

•  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. (See СНЯТИЕ И УСТАНОВКА АККУМУЛЯТОРНОЙ БАТАРЕИ [MZR-CD (RF Turbo)].)

2.  Remove the engine cover.

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

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

Turbocharger Air Outlet Pipe Removal Note

1.  Remove the battery and the battery tray. (See СНЯТИЕ И УСТАНОВКА АККУМУЛЯТОРНОЙ БАТАРЕИ [MZR-CD (RF Turbo)].)

2.  Remove the air inlet pipe fitting bolts.

3.  Remove the turbocharger air outlet pipe.

Charge Air Cooler Duct Removal Note

1.  Remove the front bumper before removing the charge air cooler duct. (See СНЯТИЕ И УСТАНОВКА ПЕРЕДНЕГО БАМПЕРА.)

Intake Shutter Valve Removal Note

1.  Drain the engine coolant before removing the Intake shutter valve. (See ЗАМЕНА ОХЛАЖДАЮЩЕЙ ЖИДКОСТИ [MZR-CD (RF Turbo)].)

Intake Manifold Removal Note

1.  Remove the supply pump, common rail and injection pipe before removing the intake manifold. (See СНЯТИЕ И УСТАНОВКА ТНВД [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 supply pump, common rail and injection pipe. (See СНЯТИЕ И УСТАНОВКА ТНВД [MZR-CD (RF Turbo)].)

Intake Shutter Valve Installation Note

1.  Refill the engine coolant after Installing the Intake shutter valve. (See ЗАМЕНА ОХЛАЖДАЮЩЕЙ ЖИДКОСТИ [MZR-CD (RF Turbo)].)

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

1.  Install a new O-ring to the charge air cooler inlet or outlet pipe.

2.  Apply grease (RFY1 13569) along the perimeter of the installed O-ring.

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Осторожно

•  If the O-ring is pinched when installing the charge air cooler inlet or outlet pipe to the charge air cooler, airtightness cannot be ensured and the charge air cooler 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 inlet or outlet pipe to the charge air cooler.

4.  Wipe away the excess grease.

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5.  Verify that the charge air cooler 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.

Air Cleaner Case Installation Note

Примечание

•  Before installing the air cleaner case, verify that the rubber mounts on the battery support bracket have not fallen off.

•  When inserting the air cleaner case into the rubber mounts, applying soapy water aids the operation.

1.  Verify that two rubber mounts are installed on the battery support bracket.

2.  Install the air cleaner case into the rubber mounts.

3.  Using the strap, secure the shroud panel and the air cleaner case as shown in the figure.

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