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Engine - Intake-Air System (L3 with TC): Removal & Installation Mazda 3 BL

Mechanical 15 illustrations ~582 words

INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]

WARNINGA 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 vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries 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 [L3 WITH TC] .)
  1. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345228-S02486648752009102000000) .)
  2. Remove the under cover and splash shield.
  3. Remove in the order indicated in the table.
  4. Install in the reverse order of removal.
  5. Complete the "AFTER REPAIR PROCEDURE". (See «AFTER SERVICE PRECAUTION [L3 WITH TC]»(ref-345226-S16448250982009102000000) .)

Scheme 316

Scheme 316
Scheme 316

Scheme 317

Scheme 317: Air Cleaner Removal Note
Scheme 317: Air Cleaner Removal Note

Scheme 318

Scheme 318
Scheme 318

Scheme 319

Scheme 319
Scheme 319

Scheme 320

Scheme 320
Scheme 320
  1. Remove the slide rubber mount shown in the figure in the following procedure: Pull out the checker tab shown in the figure. Slide the slide rubber mount in the direction shown by the arrow while pulling up the rubber.
  2. Remove the air cleaner.
  3. Remove the strap shown in the figure.

Scheme 321

Scheme 321: Charge Air Cooler Removal Note
Scheme 321: Charge Air Cooler Removal Note
  1. Remove the charge air cooler duct.
  2. Remove the charge air cooler cover.
  3. Remove the charge air cooler.
  4. Remove the charge air cooler bracket.

Air Hose Removal Note

  1. Disconnect the variable swirl shutter valve switch connector.
  2. Disconnect the fuel injector harness connector.
  3. Disconnect the ventilation hose connected to the air hose.
  4. Remove the air hose.

Air Duct Removal Note

  1. Disconnect the wastegate control solenoid valve connector.
  2. Disconnect the purge solenoid valve connector.
  3. Disconnect the EGR valve connector.
  4. Remove the air duct.

Throttle Body Removal Note

  1. Disconnect the throttle body connector.
  2. Drain the engine coolant before removing the water hose. (See «ENGINE COOLANT REPLACEMENT [L3 WITH TC]»(ref-345232-S19309368322009102000000) .)
  3. Remove the throttle body.

Scheme 322

Scheme 322: Intake Manifold Removal Note
Scheme 322: Intake Manifold Removal Note
  1. Remove the fuel delivery pipe cover.
  2. Disconnect the quick connector connected to the intake manifold.
  3. Remove the EGR pipe.
  4. Disconnect the variable swirl solenoid valve connector.
  5. Remove the oil level gauge pipe. (See «OIL PAN REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345230-S14438765802009102000000) .)
  6. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345224-S04793494252009102000000) .)
  7. Set the power steering oil pump out of the way.
  8. Disconnect the fuel pressure sensor connector.
  9. Disconnect the brake vacuum hose.
  10. Disconnect the MAP sensor connector.
  11. Remove the intake manifold installation bolts.
  12. Disconnect the evaporative hose connected between the intake manifold and the PCV valve from the intake manifold.
  13. Remove the intake manifold.

Scheme 323

Scheme 323: Turbocharger Removal Note
Scheme 323: Turbocharger Removal Note

Scheme 324

Scheme 324
Scheme 324
  1. Remove the TWC. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  2. Disconnect the rear HO2S
  3. Remove the insulator (Exhaust manifold upper side). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  4. Set the generator duct out of the way. (See «GENERATOR REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345228-S13698567152009102000000) .)
  5. Remove the insulator (Exhaust manifold lower side). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  6. Remove the insulator (WU-TWC top side). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  7. Remove the front HO2S. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  8. Remove the WU-TWC. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  9. Remove the oil pipe, water pipe, and insulator.
  10. Remove the turbocharger.

Scheme 325

Scheme 325: Turbocharger Installation Note
Scheme 325: Turbocharger Installation Note

Scheme 326

Scheme 326
Scheme 326

Scheme 327

Scheme 327
Scheme 327
  1. Install the turbocharger. Tightening torque 38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}
  2. Install the WU-TWC. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  3. Install the front HO2S. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-345231-S40614846362009102000000) .)
  4. Install the insulator.
  5. Install the water pipes and oil pipe, then insert the water hose until it reaches the stopper.

Scheme 328

Scheme 328: Wastegate Control Solenoid Valve Installation Note
Scheme 328: Wastegate Control Solenoid Valve Installation Note
  1. Install the wastegate control solenoid valve. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 70-95 in.lbf}
  2. Install the hose as shown in the figure.

Scheme 329

Scheme 329: Throttle Body Installation Note
Scheme 329: Throttle Body Installation Note
  1. Tighten the throttle body installation bolts in the order shown in the figure. Tightening torque 8-11.5 N.m {82-117 kgf.cm, 71-101 in.lbf}

Scheme 330

Scheme 330: Strap Installation Note
Scheme 330: Strap Installation Note
  1. Using the strap, secure the shroud panel and the air cleaner case as shown in the figure.

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