Mazda 3 Service Manual: Intake Air System Removal/Installation [Mzr 2.0, Mzr 2.5]

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.

• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

1. Complete the “BEFORE SERVICE PRECAUTION”..

2. Remove the battery cover..

3. Disconnect the negative battery cable..

4. Remove the plug hole plate..

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.

9. Inspect the engine coolant level..

10. Inspect for engine coolant leakage..

11. Complete the “AFTER SERVICE PRECAUTION”..

Step 1

Step 2

Air Cleaner Cover Removal Note

1. Remove the air cleaner cover and resonance chamber and air hose as single unit.

2. Remove the air cleaner cover.

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).

Throttle Body 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.

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 throttle body and plug the water hose quickly.

Intake Manifold Removal Note

1. Remove the aerodynamic under cover No.2..

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

3. Disconnect the vacuum hoses connecting the intake manifold.

4. Remove the fuel distributor and fuel injector a as single unit..

5. Remove the intake manifold.

Throttle Body Installation Note

1. Temporarily tighten the throttle body to the intake manifold.

2. Tighten the installation bolts in the order shown in the figure.

Throttle body tightening torque

• 8—11 N·m {82—112 kgf·cm, 71—97 in·Ibf}

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

Air Hose Installation Note

1. Adjust the convex of the throttle body to the recess of the air hose.