INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, 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.
•  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”.
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.

Without Set Bolt

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 1.5, MZR 1.6].)

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

4.  Remove in the order indicated in the table.

5.  Disconnect the wiring harness.

6.  Install in the reverse order of removal.

7.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 1.5, MZR 1.6].)

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1
Fresh-air duct No.2
2
Fresh-air duct No.1
3
PCM connector cover
4
PCM connector
(See PCM Connector Connection Note (Without Set Bolt).)
5
Air cleaner cover
6
Air cleaner element
7
Air cleaner case
8
Ventilation hose (air hose side)
9
Air hose
(See Air Hose Removal Note.)
10
Water hose
(See Water Hose Removal Note.)
11
Throttle body
12
Evaporative hose (to purge solenoid valve)
13
Vacuum hose (to master back)
14
PCV hose (intake manifold side)
15
Intake manifold
(See Intake Manifold Removal Note.)


With Set Bolt

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 1.5, MZR 1.6].)

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

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 [MZR 1.5, MZR 1.6].)
(2)  Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6])
(3)  Disconnect the MAF/IAT sensor connector.
(4)  Remove the air cleaner cover.

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

6.  Disconnect the wiring harness.

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR 1.5, MZR 1.6].)

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1
Fresh-air duct No.2
2
Fresh-air duct No.1
3
Air cleaner element
4
Air cleaner case
5
Ventilation hose (air hose side)
6
Air hose
(See Air Hose Removal Note.)
7
Water hose
(See Water Hose Removal Note.)
8
Throttle body
9
Evaporative hose (to purge solenoid valve)
10
Vacuum hose (to master back)
11
PCV hose (intake manifold side)
12
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.


Water Hose Removal Note

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.5, MZR 1.6].)

2.  Disconnect the water hose.


Intake Manifold Removal Note

1.  Remove the fuel distributor and fuel injector as a single unit. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

2.  Remove the EGR pipe (intake manifold side). (Vehicles with EGR system) (See EGR PIPE REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

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

4.  Remove the intake manifold.


PCM Connector Connection Note (Without Set Bolt)

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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