INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.6]

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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.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

2.  Disconnect the wiring harness.

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

5.  Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [MZR 1.6].)

6.  Inspect the engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZR 1.6].)

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 1.6].)

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1
Ventilation hose
2
Resonance chamber
(See Resonance Chamber Removal Note.)
3
Air hose
4
Air cleaner cover
5
Air cleaner element
6
Fresh-air duct
7
Air cleaner case
8
Water hose
(See Water Hose Removal Note.)
(See Water Hose Installation Note.)
9
Throttle body
(See Throttle Body Removal Note.)
10
PCV hose
11
Intake manifold
(See Intake Manifold Removal Note.)
12
Vacuum hose


Resonance Chamber Removal Note

1.  Remove the MAF sensor/IAT sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [MZR 1.6].)

2.  Remove the following parts as a single unit:

•  Air hose
•  Air cleaner cover
•  Air cleaner element
•  Air cleaner case
•  Fresh-air duct
•  Resonance chamber

3.  Remove the resonance chamber.


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 engine coolant hose with a sharp-edged object. Otherwise, the hose could be damaged.

1.  Wrap a clean cloth around the cooling system cap and release the pressure by loosening the cap slowly.

2.  Remove the engine coolant hose from the throttle body and plug the engine coolant hose quickly.


Throttle Body Removal Note

1.  Disconnect the throttle body connector.

2.  Remove the Throttle body.


Intake Manifold Removal Note

1.  Remove all clips for securing water hose from the intake manifold.

2.  Remove all clips for securing wiring harnesses from the intake manifold.

3.  Set aside the fuel distributor and fuel injector as a single unit as shown in the figure.

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4.  Remove the intake manifold.


Water Hose Installation Note

1.  Remove the plug from the engine coolant hose and install the engine coolant hose to the throttle body quickly.