Fuel Delivery and Air Induction: Service and Repair
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]
WARNING:
- 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.
1. Remove the battery cover. Removal and Replacement
2. Disconnect the negative battery cable. Removal and Replacement
3. Remove the battery and battery tray. Removal and Replacement
4. Remove the splash shield (RH) and aerodynamic under cover No.2 as a single unit. Aerodynamic Under Cover No. 2 Removal/Installation Splash Shield Removal/Installation
5. Disconnect the wiring harness.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing. (Turbocharger not removed)
9. Refill the engine coolant. (Turbocharger removed)
10. Inspect the engine coolant level. Engine Coolant Level Inspection
11. Inspect for engine coolant leakage. Engine Coolant Leakage Inspection
Air Cleaner Cover Removal Note
1. Remove the air cleaner cover and air hose as single unit.
2. Remove the air cleaner cover.
Air Hose Removal Note
1. Disconnect the variable swirl shutter valve switch connector.
2. Disconnect the fuel injector harness connector.
3. Disconnect the ventilation hose connected to the air hose.
4. Remove the air hose.
Fresh-Air Duct (No.1) Removal Note
1. Remove the fresh-air duct (No.1) and fresh-air duct (No.2) as single unit.
2. Remove the fresh-air duct (No.1).
Air Duct Removal Note
1. Disconnect the wastegate control solenoid valve connector.
2. Disconnect the purge solenoid valve connector.
3. Disconnect the EGR valve connector.
4. Remove the air duct.
Throttle Body Removal Note
Turbocharger not removed
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.
NOTE:
- If the turbocharger is not removed at the same time (if only throttle body is removed), remove the throttle body without draining the engine coolant.
1. Disconnect the throttle body connector.
2. Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.
3. Remove the water hose from the throttle body and plug the water hose quickly.
4. Remove the throttle body.
Turbocharger removed
NOTE:
- If the turbocharger is removed at the same time, drain the engine coolant and remove the throttle body.
1. Disconnect the throttle body connector.
2. Drain the engine coolant before disconnect the water hose. Service and Repair
3. Remove the throttle body.
Intake Manifold Removal Note
1. Remove the fuel delivery pipe cover.
2. Disconnect the quick connector connected to the intake manifold.
3. Remove the EGR pipe. Service and Repair
4. Disconnect the variable swirl solenoid valve connector.
5. Disconnect the OCV connector.
6. Remove the oil level gauge pipe. Service and Repair
7. Remove the drive belt. Service and Repair
8. Set the electric power steering oil pump out of the way. Removal and Replacement
9. Disconnect the fuel pressure sensor connector.
10. Disconnect the vacuum hose connected between the intake manifold and the master cylinder from the intake manifold.
11. Disconnect the MAP sensor connector.
12. Remove the intake manifold installation bolts.
13. Disconnect the evaporative hose connected between the intake manifold and the PCV valve from the intake manifold.
14. Remove the intake manifold.
Turbocharger Insulator Removal Note
1. Remove the exhaust manifold upper insulator. Service and Repair
2. Remove the turbocharger insulator.
Oil Outlet Pipe Removal Note
1. Set the generator duct out of the way. Removal and Replacement
2. Remove the oil outlet pipe.
Water Outlet Pipe Removal Note
1. Drain the engine coolant. Service and Repair
2. Remove the water outlet pipe.
Turbocharger Removal Note
1. Remove the HO2S. Heated Oxygen Sensor (HO2S) Removal/Installation
2. Remove the A/F sensor. Air Fuel Ratio (A/F) Sensor Removal/Installation
3. Remove the WU-TWC insulator. Service and Repair
4. Remove the exhaust manifold lower insulator. Service and Repair
5. Remove the TWC. Service and Repair
6. Remove the WU-TWC. Service and Repair
7. Remove the oil outlet pipe, oil inlet pipe, water pipe, and turbocharger insulator.
8. Remove the turbocharger.
Turbocharger Installation Note
1. Install the turbocharger.
2. Install the WU-TWC. Service and Repair
3. Install the A/F sensor. Air Fuel Ratio (A/F) Sensor Removal/Installation
4. Install the HO2S. Heated Oxygen Sensor (HO2S) Removal/Installation
5. Tight the oil inlet pipe installation bolt while the stopper of the water outlet pipe is faced to the installation area, then install the turbocharger insulator.
6. Install the oil outlet pipe and water inlet pipe, then insert the water hose until it reaches the stopper.
Wastegate Control Solenoid Valve Installation Note
1. Install the wastegate control solenoid valve.
2. Install the vacuum hose as shown in the figure.
Throttle Body Installation Note
1. Temporarily tighten the throttle body to the intake manifold.
2. Tighten the throttle body installation bolts in the order shown in the figure.
Tightening torque
- 8-11 Nm {82-112 kgf-cm, 71-97 in-lbf}
3. Remove the plug from the engine coolant hose and install the water hose to the throttle body quickly. (Turbocharger not removed)
4. Install the water hose to the throttle body. (Turbocharger removed)