INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZJ, ZY]

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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.
•  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”.
Caution
•  The PCM is built into the air cleaner cover. Applying excessive pressure to the cover could damage the PCM. Be careful not to put your hands on the PCM during the removal/installation.
•  Removing the PCM from the air cleaner could damage the sealing or the circuitry. Do not remove the PCM from the air cleaner.
•  Removing the fresh-air duct from the air cleaner case may damage the fresh-air duct. Remove the fresh-air duct and the air cleaner case as a single unit except when the fresh-air duct is to be replaced with a new one.

Except U.K. Specs.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [ZJ, ZY].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

5.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [ZJ, ZY].)

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1
Fresh-air duct
2
PCM connector cover
3
PCM connector
(See PCM Connector Connection Note.)
4
MAF/IAT sensor connector
5
Air cleaner cover
6
Air cleaner element
7
Air cleaner case
8
Ventilation hose (air hose side)
9
Air hose
10
Engine coolant hose
(See Engine Coolant Hose Removal Note.)
11
Throttle body
12
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZJ, ZY].)
13
Fuel distributor component
(See FUEL INJECTOR REMOVAL/INSTALLATION [ZJ, ZY].)
14
Variable intake air shutter valve actuator connector (With variable intake air system)
15
Variable tumble shutter valve actuator connector
16
MAP sensor connector
17
Evaporative hose (to purge solenoid valve)
18
Vacuum hose (to master back)
19
PCV hose (intake manifold side)
20
Intake manifold
(See Intake Manifold Removal Note.)


U.K. Specs.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [ZJ, ZY].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

Caution
•  New set bolts are required when reinstalling the PCM connector cover. Perform Step 4 only when removing the air cleaner cover.

3.  When removing the air cleaner cover, perform the following procedure and go to Step 6.

(1)  Remove the PCM connector cover. (See PCM REMOVAL/INSTALLATION [ZJ, ZY].)
(2)  Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [ZJ, ZY])
(3)  Disconnect the MAF/IAT sensor connector.
(4)  Remove the air cleaner cover.

4.  Set the air cleaner cover out of the way.

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [ZJ, ZY].)

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1
Fresh-air duct
2
Air cleaner element
3
Air cleaner case
4
Ventilation hose (air hose side)
5
Air hose
6
Engine coolant hose
(See Engine Coolant Hose Removal Note.)
7
Throttle body
8
Quick release connector
(See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [ZJ, ZY].)
9
Fuel distributor component
(See FUEL INJECTOR REMOVAL/INSTALLATION [ZJ, ZY].)
10
Variable intake air shutter valve actuator connector (With variable intake air system)
11
Variable tumble shutter valve actuator connector
12
MAP sensor connector
13
Evaporative hose (to purge solenoid valve)
14
Vacuum hose (to master back)
15
PCV hose (intake manifold side)
16
Intake manifold
(See Intake Manifold Removal Note.)


Air Hose Removal Note

1.  Move the purge solenoid valve slightly out of the way without removing the air hose.


Engine Coolant Hose Removal Note

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [ZJ, ZY].)

2.  Disconnect the engine coolant hose.


Intake Manifold Removal Note

1.  Remove the EGR pipe (intake manifold side). (See EGR PIPE REMOVAL/INSTALLATION [ZJ, ZY].)

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

3.  Remove the intake manifold.


PCM Connector Connection Note

Caution
•  If the PCM connector is inserted at an angle and the lever is moved, the connector could be damaged. Verify that the PCM connector is inserted straight.
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1.  Verify that the PCM connector lever is tilted towards the wiring harness side as shown in the figure.

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2.  Insert the PCM connector straight until it contacts the PCM and verify that the lever reverts upward naturally.

3.  Push the lever until a click is heard.

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