INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZJ, ZY, Z6]

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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”. (See BEFORE SERVICE PRECAUTION[ZJ, ZY, Z6].)
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.

Except U.K. Specs.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION[ZJ, ZY, Z6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION[ZJ, ZY, Z6].)

3.  Remove the under cover.

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

6.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[ZJ, ZY, Z6].)

7.  Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing.

8.  Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [ZJ, ZY, Z6].)

9.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [ZJ, ZY, Z6].)

Without throttle valve actuator

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1
PCM connector cover
2
PCM connector
(See PCM Connector Installation Note.)
3
Air cleaner cover
4
Air cleaner element
5
Air cleaner case
6
Fresh-air duct cover
7
Strap
(See Strap Installation Note.)
8
Fresh-air duct
(See Fresh-air Duct Installation Note.)
9
Air hose
(See Air Hose Installation Note (Without Throttle Valve Actuator).)
10
Throttle body
(See Throttle Body Removal Note (Without Throttle Valve Actuator).)
11
Fuel distributor
(See FUEL INJECTOR REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
12
Intake manifold
(See Intake Manifold Removal Note (Without Throttle Valve Actuator).)

With throttle valve actuator

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1
PCM connector cover
2
PCM connector
(See PCM Connector Installation Note.)
3
Air cleaner cover
4
Air cleaner element
5
Air cleaner case
6
Fresh-air duct cover
7
Strap
(See Strap Installation Note.)
8
Fresh-air duct
(See Fresh-air Duct Installation Note.)
9
Air hose
(See Air Hose Removal Note (With Throttle Valve Actuator).)
10
Engine coolant hose
(See Engine Coolant Hose Removal Note (With Throttle Valve Actuator).)
(See Engine Coolant Hose Installation Note (With Throttle Valve Actuator).)
11
Throttle body
12
EGR pipe (Intake manifold side)
(See EGR Pipe Installation Note (With Throttle Valve Actuator).)
13
Fuel distributor
(See FUEL INJECTOR REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
14
Intake manifold
(See Intake Manifold Removal Note (With Throttle Valve Actuator).)


U.K. Specs.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION[ZJ, ZY, Z6].)

2.  Disconnect the negative battery cable.

3.  Remove the under cover.

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

4.  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, Z6].)
(2)  Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [ZJ, ZY, Z6].)
(3)  Remove the air cleaner cover.

5.  Set the air cleaner out of the way.

6.  Remove in the order indicated in the table.

7.  Install in the reverse order of removal.

8.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION[ZJ, ZY, Z6].)

9.  Add the engine coolant to the cooling system filler neck and the coolant reserve tank to replace that during servicing.

10.  Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [ZJ, ZY, Z6].)

11.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [ZJ, ZY, Z6].)

am3zzw00013115

1
Air cleaner element
2
Air cleaner case
3
Fresh-air duct cover
4
Strap
(See Strap Installation Note.)
5
Fresh-air duct
(See Fresh-air Duct Installation Note.)
6
Air hose
(See Air Hose Installation Note (Without Throttle Valve Actuator).)
7
Throttle body
(See Throttle Body Removal Note (Without Throttle Valve Actuator).)
(See Engine Coolant Hose Installation Note (With Throttle Valve Actuator).)
8
Fuel distributor
(See FUEL INJECTOR REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
9
Intake manifold
(See Intake Manifold Removal Note (Without Throttle Valve Actuator).)


Air Hose Removal Note (With Throttle Valve Actuator)

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


Engine Coolant Hose Removal Note (With Throttle Valve Actuator)

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 (Without Throttle Valve Actuator)

1.  Remove the purge solenoid valve. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION[ZJ, ZY, Z6].)


Intake Manifold Removal Note (Without Throttle Valve Actuator)

1.  Disconnect the engine coolant hose from the engine coolant pipe as shown in the figure.

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2.  Remove the accelerator cable bracket from the intake manifold.

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Intake Manifold Removal Note (With Throttle Valve Actuator)

1.  Remove the clip shown in the figure.

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2.  Loosen the intake manifold bolts and set the intake manifold aside for easier access.

3.  Remove the clip shown in the figure and set the engine coolant hose out of the way.

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EGR Pipe Installation Note (With Throttle Valve Actuator)

1.  Remove in the order indicated shown in the figure.

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Engine Coolant Hose Installation Note (With Throttle Valve Actuator)

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


Air Hose Installation Note (Without Throttle Valve Actuator)

1.  Align the alignment marks on the throttle body and the air hose.

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Strap Installation Note

1.  Using the strap, secure the shroud panel and the fresh-air duct as shown in the figure.

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Fresh-air Duct Installation Note

Note
•  Before installing the fresh-air duct, verify that the rubber mounts on the battery support bracket have not fallen off.
•  When inserting the fresh-air duct 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 fresh-air duct into the rubber mounts.


PCM Connector Installation Note

1.  Insert the PCM connector fully into the air cleaner and push the lever until a click is heard.

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