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Engine - Intake-Air System: Removal & Installation Mazda CX-7 I facelift

Mechanical 7 illustrations ~711 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] ).

Scheme 171

Scheme 171
Scheme 171
  1. Disconnect the negative battery cable.
  2. Remove the charge air cooler duct.
  3. Remove the battery and battery tray. (See «BATTERY REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343783-S22929626792009101500000) ).
  4. Remove the under cover.
  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 [L3 WITH TC]»(ref-343778-S22287912042009101500000) ).

Resonance Chamber Removal Note

  1. Remove the mudguard (LF).
  2. Remove the resonance chamber.

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. ATF gage pipe out of the way.
  5. 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-343779-S08745490832009101500000) ).
  3. Remove the throttle body.

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. Disconnect the OCV connector.
  6. Disconnect the PSP switch connector.
  7. Remove the oil level gauge pipe. (See «OIL PAN REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343776-S40621167912009101500000) ).
  8. Remove the splash shield (RF).
  9. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343774-S21935724792009101500000) ).
  10. Set the power steering oil pump out of the way.
  11. Disconnect the fuel pressure sensor connector.
  12. Disconnect the vacuum hose connected between the intake manifold and the master cylinder from the intake manifold.
  13. Disconnect the MAP sensor connector.
  14. Remove the intake manifold installation bolts.
  15. Disconnect the evaporative hose connected between the intake manifold and the PCV valve from the intake manifold.
  16. Remove the intake manifold.

Scheme 172

Scheme 172: Turbocharger Removal Note
Scheme 172: Turbocharger Removal Note

Scheme 173

Scheme 173
Scheme 173
  1. Remove the middle pipe (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  2. Disconnect the rear HO2S connector.
  3. Remove the front pipe. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ). CAUTION: When removing the cowl grille, a part or tool may hit the edge of the windshield and could damage it. Protect the windshield by covering it with a clean rag to prevent damage to the windshield.
  4. Remove the cowl grille. (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-343791-S10664681202009101500000) ).
  5. Remove the windshield wiper motor.
  6. Remove the cowl panel.
  7. Remove the insulator (Exhaust manifold upper side). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  8. Set the generator out of the way. (See «GENERATOR REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343783-S09046648482009101500000) ).
  9. Remove the insulator (Exhaust manifold lower side). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  10. Disconnect the front HO2S connector.
  11. Remove the insulator (WU-TWC top side). (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  12. Remove the vacuum hose (Brake master back side).
  13. Remove the front HO2S. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  14. Remove the WU-TWC. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  15. Remove the oil pipes, water pipe, and insulator.
  16. Remove the turbocharger.

Scheme 174

Scheme 174: Turbocharger Installation Note
Scheme 174: Turbocharger Installation Note

Scheme 175

Scheme 175
Scheme 175
  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-343777-S32611220982009101500000) ).
  3. Install the front HO2S. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 WITH TC]»(ref-343777-S32611220982009101500000) ).
  4. Tighten the oil pipe installation bolt while the stopper of the oil pipe is facing the installation area, then install the insulator.
  5. Install the oil pipe and water pipe, then insert the water hose until it reaches the stopper.

Scheme 176

Scheme 176: Wastegate Control Solenoid Valve Installation Note
Scheme 176: 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 177

Scheme 177: Throttle Body Installation Note
Scheme 177: 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}

Air Cleaner Case Installation Note

CAUTIONBefore assembling the air cleaner, verify that the rubber mounts have not fallen off from the air cleaner bracket (3 locations). Always install the air cleaner case using the following procedure.

Note. When inserting the rubber mounts into the air cleaner case, soapy water can be applied.

  1. Verify that the rubber mounts are set in the air cleaner bracket (3 locations).
  2. Install the projections on the frame side (2 locations).
  3. Verify that the projections on the frame side are installed securely.
  4. Install the projection on the engine side (remaining location).
  5. Verify that the projection on the engine side installed securely.

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