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Engine - Intake-Air System (Lf 2.0L): Removal & Installation Mazda MX-5 NC рестайлинг

Mechanical 19 illustrations ~1601 words

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]

WARNINGA hot engine and intake-air system can cause severe bums. Turn off the engine and wart until they are coot 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", while referring to the "BEFORE SERVICE PRECAUTIONS".
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  3. Remove in the order indicated in the table in the figure(s).
  4. Install in the reverse order of removal.
  5. Add the engine coolant to the cooling system filter neck and the coolant reserve tank to replace that during servicing.
  6. Inspect the engine coolant level. (See «ENGINE COOLANT LEVEL INSPECTION [LF]»(ref-430330-S29859654622011101700000) ).
  7. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [LF]»(ref-430330-S18929504142011101700000) ).

Scheme 152

Scheme 152: Step 1 (Except 6MT)
Scheme 152: Step 1 (Except 6MT)

Scheme 153

Scheme 153: Step 1 (6MT)
Scheme 153: Step 1 (6MT)

Scheme 154

Scheme 154: Step 2
Scheme 154: Step 2

Air Cleaner Cover Removal Note

  1. Remove the MAF/IAT sensor. (See «MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [LF]»(ref-478574-S17568210822012061100000) ).
  2. Remove the air cleaner cover.

Fresh-air Duct Removal Note

  1. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-430315-S08524033602011101700000) ).
  2. Remove the fresh-air duct.

Throttle Body Removal Note

WARNINGTurn 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.
CAUTIONDo 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.

Scheme 155

Scheme 155: Dynamic Chamber Removal Note
Scheme 155: Dynamic Chamber Removal Note

Scheme 156

Scheme 156
Scheme 156

Scheme 157

Scheme 157
Scheme 157

Scheme 158

Scheme 158
Scheme 158

Scheme 159

Scheme 159
Scheme 159

Scheme 160

Scheme 160
Scheme 160

Scheme 161

Scheme 161
Scheme 161
  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-430300-S30731392202011101700000) )
  2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) ).
  3. Remove the following parts: Remove the front suspension tower bar (joint), (right side) and (left side). (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-430328-S00590495132011101700000) . Remove the wiper arm and blade. (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-430319-S25003605892011101700000) ). Remove the cowl grille. (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S16213158202011101700000) ). Remove the side cowl grille. (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S14993642892011101700000) ). Move the cooler pipe No. 3 and heater pipe slightly out of the way. Remove the service hole cover.
  4. Disconnect the heater hose and move the heater pipe slightly out of the way.
  5. Disconnect the heater hose and move the heater hose slightly out of the way.
  6. Remove the harness bracket.
  7. Remove the under cover. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-430328-S39020638982011101700000) ).
  8. Disconnect the variable intake air solenoid valve connector, variable tumble solenoid valve connector (AT), EGR valve connector, CMP sensor connector and PSP switch connector.
  9. Disconnect the ignition coil connector and fuel injector connector and move the harness slightly out of the way.
  10. Disconnect the quick release connector from the fuel distributor. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S31748830442011101700000) ).
  11. Remove the fuel distributor. (See «FUEL INJECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S22101311922011101700000) ).
  12. Disconnect the water hose from the EGR valve.
  13. Disconnect two water hoses from the thermostat.
  14. Remove the heater hose and heater pipe from the dynamic chamber.
  15. Remove the variable intake air solenoid valve. (See «VARIABLE INTAKE AIR SOLENOID VALVE REMOVAL/INSTALLATION [LF]»(ref-478572-S10197431922012061100000) ).
  16. Remove the variable tumble solenoid valve (AT). (See «VARIABLE TUMBLE SOLENOID VALVE REMOVAL/INSTALLATION [LF]»(ref-478572-S16719948482012061100000) ).
  17. Remove the dynamic chamber installation bolts.
  18. Remove the EGR pipe.
  19. Disconnect the connector from the A/C compressor.
  20. Disconnect the KS connector.
  21. Move the vacuum hose between the purge solenoid valve and the charcoal canister slightly out of the way.
  22. Move the clutch release cylinder slightly out of the way. (MT) (See «CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION»(ref-478577-S36199607162012061100000) ).
  23. Disconnect the evaporative hose with the dynamic chamber raised.
  24. Remove the dynamic chamber.
  25. Remove the variable intake air shutter valve actuator. (See «VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]»(ref-478572-S40553346962012061100000) ).
  26. Remove the MAP sensor. (See «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION [LF]»(ref-478574-S35617767962012061100000) ).

Intake Manifold Removal Note

  1. Remove the intake manifold.
  2. Remove the variable tumble shutter valve actuator (AT). (See «VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]»(ref-478572-S32866336882012061100000) ).

Scheme 162

Scheme 162: Throttle Body Installation Note
Scheme 162: Throttle Body Installation Note
  1. Temporarily tighten the throttle body to the dynamic chamber.
  2. Tighten the bolts in the order as shown in the figure. Throttle body tightening torque 8.0-11.5 N.m {82-110 kgf.cm, 71-100 in.lbf}
  3. Remove the plug from the engine coolant hose and install the water hose to the throttle body quickly.

VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]

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 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", while referring to the "BEFORE SERVICE PRECAUTIONS".

Scheme 163

Scheme 163
Scheme 163

Scheme 164

Scheme 164
Scheme 164
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  3. Remove the throttle body. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ).
  4. Disconnect the quick release connector. (See «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF]»(ref-430327-S01122655752011101700000) ).
  5. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-430300-S30731392202011101700000) )
  6. Remove the service hole cover. Remove the front suspension tower bar (joint), (right side) and (left side). (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-430328-S00590495132011101700000) . Remove the wiper arm and blade. (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-430319-S25003605892011101700000) ). Remove the cowl grille. (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S16213158202011101700000) ). Remove the side cowl grille. (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S14993642892011101700000) ). Remove the service hole cover.
  7. Remove the harness bracket.
  8. Remove the under cover. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-430328-S39020638982011101700000) ).
  9. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) ).
  10. Disconnect the quick release connector from the fuel distributor. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S31748830442011101700000) ).
  11. Remove the fuel distributor. (See «FUEL INJECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S22101311922011101700000) ).
  12. Move the clutch release cylinder slightly out of the way. (MT) (See «CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION»(ref-478577-S36199607162012061100000) ).
  13. Remove the dynamic chamber. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ).
  14. Remove in the order indicated in the table.
  15. Install in the reverse order of removal.

Scheme 165

Scheme 165: Variable Intake Air Shutter Valve Actuator Removal Note
Scheme 165: Variable Intake Air Shutter Valve Actuator Removal Note
  1. Disengage the variable intake air shutter valve actuator rod from the dynamic chamber on the opposite side using a suitable screwdriver or equivalent too! as shown in the figure. CAUTION: Do not remove the lever, otherwise the variable intake air shutter valve opening angle will deviate. To prevent removal of the lever when removing the variable intake shutter valve actuator, press the lever firmly to the dynamic chamber side by hand.

Variable Intake Air Shutter Valve Actuator Installation Note

  1. Press the variable intake air shutter valve actuator rod into the dynamic chamber on the opposite side until a click is heard, and install it.

Scheme 166

Scheme 166
Scheme 166
  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-430300-S30731392202011101700000) )
  2. Remove the following parts: Front suspension tower bar (joint), (right side) and (left side) (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-430328-S00590495132011101700000) . Wiper arm and blade (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-430319-S25003605892011101700000) ). Cowl grille (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S16213158202011101700000) ). Side cowl grille (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S14993642892011101700000) ). Service hole cover
  3. Disconnect the vacuum hose from the variable intake air solenoid valve.
  4. Connect a vacuum pump to the vacuum hose. NOTE: Verify that the variable intake air shutter valve actuator rod moves using a mirror.
  5. Apply vacuum and verify that the rod moves. Vacuum kPa {mmHg, inHg} Rod movement Below -2.7 {-21, -0.9} Not operate Above -33.4 {-251, -9.89} Fully pulled If the rod does not move, replace the variable intake air shutter valve actuator. (See «VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]»(ref-478572-S40553346962012061100000) ).

AT

  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-430300-S30731392202011101700000) )
  2. Remove the following parts: Front suspension tower bar (joint), (right side) and (left side) (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-430328-S00590495132011101700000) . Wiper arm and blade (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-430319-S25003605892011101700000) ). Cowl grille (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S16213158202011101700000) ). Side cowl grille (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S14993642892011101700000) ). Service hole cover
  3. Disconnect the vacuum hose from the variable tumble solenoid valve.
  4. Connect a vacuum pump to the vacuum hose. NOTE: Verify that the variable tumble shutter valve actuator rod moves using a mirror.
  5. Apply vacuum and verify that the rod moves. Vacuum kPa {mmHg, inHg} Rod movement Below -2.7 {-21, -0.9} No operate Above -33.4 {-251, -9.89} Fully pulled If the rod dose not move, replace the variable tumble shutter valve actuator. (See «VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]»(ref-478572-S32866336882012061100000) ).
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 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", while referring to the "BEFORE SERVICE PRECAUTIONS".

Scheme 167

Scheme 167
Scheme 167

Scheme 168

Scheme 168
Scheme 168
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  3. Remove the throttle body. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ).
  4. Disconnect the quick release connector. (See «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF]»(ref-430327-S01122655752011101700000) ).
  5. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-430300-S30731392202011101700000) )
  6. Remove the service hole cover. Remove the front suspension tower bar (joint), (right side) and (left side). (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-430328-S00590495132011101700000) . Remove the wiper arm and blade. (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-430319-S25003605892011101700000) ). Remove the cowl grille. (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S16213158202011101700000) ). Remove the side cowl grille. (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-430307-S14993642892011101700000) ). Remove the service hole cover.
  7. Remove the harness bracket.
  8. Remove the under cover. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-430328-S39020638982011101700000) ).
  9. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-430308-S13106615682011101700000) ).
  10. Disconnect the quick release connector from the fuel distributor. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S31748830442011101700000) ).
  11. Remove the fuel distributor. (See «FUEL INJECTOR REMOVAL/INSTALLATION [LF]»(ref-430308-S22101311922011101700000) ).
  12. Remove the dynamic chamber. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ).
  13. Remove the intake manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-478572-S27568218632012061100000) ).
  14. Remove in the order indicated in the table in figure.
  15. Install in the reverse order of removal.

Scheme 169

Scheme 169: Variable Tumble Shutter Valve Actuator Removal Note
Scheme 169: Variable Tumble Shutter Valve Actuator Removal Note
  1. Disengage the variable tumble shutter valve actuator rod from the intake manifold using a suitable screwdriver or equivalent tool as shown in the figure.

Variable Tumble Shutter Valve Actuator Installation Note

  1. Press the variable tumble shutter valve actuator into the variable tumble shutter valve actuator rod and the intake manifold on the opposite side until a dick is heard, and install it.

Scheme 170

Scheme 170: ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF]
Scheme 170: ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF]
  1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-430294-S35932810402011101700000) ).
  3. Remove in the order indicated in the table in figure.
  4. Install in the reverse order of removal.

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