Fuel Delivery and Air Induction: Service and Repair

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5]

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 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.
- Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.

1. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

2. Disconnect the negative battery cable. Removal and Replacement

3. Disconnect the wiring harness.

4. Remove in the order indicated in the table.

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

6. Inspect the engine coolant level. Engine Coolant Level Inspection

7. Inspect for engine coolant leakage. Engine Coolant Leakage Inspection

8. Install in the reverse order of removal.

9. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution









Air Cleaner Cover Removal Note

1. Remove the MAF/IAT sensor. Service and Repair

2. Remove the air cleaner cover.

Air Hose Removal Note

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

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 fuel distributor and fuel injector as a single unit. Service and Repair

2. Remove the EGR pipe (intake manifold side). Service and Repair

3. Remove the MAP sensor. Service and Repair

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

5. Remove the intake manifold.

Throttle Body Installation Note

1. Install the throttle body to the intake manifold.

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

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.






1. Verify that the PCM connector lever is tilted towards the wiring harness side as shown in the figure.






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.