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Engine - Intake-Air System: Removal & Installation Mazda RX-8 I

Mechanical 12 illustrations ~560 words

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

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 REPAIR PROCEDURE .

Scheme 16

Scheme 16
Scheme 16
  1. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  2. Remove in the order indicated. (Scheme 16)
  3. Install in the reverse order of removal.

Fresh-Air Duct Removal Note

  1. Remove the front bumper.

Scheme 17

Scheme 17: Fresh-Air Duct Installation Note
Scheme 17: Fresh-Air Duct Installation Note
  1. Install the clips.
  2. Tighten the bolt to the specified torque. Tightening torque 7.8-10.8 N.m {79-111 kgf.cm, 69.0-95.6 in.lbf}

Scheme 18

Scheme 18: Air Cleaner Insulator Installation Note
Scheme 18: Air Cleaner Insulator Installation Note
  1. Temporarily tighten nuts.
  2. Temporarily tighten bolts.
  3. Tighten the nuts to the specified torque.
  4. Tighten the bolts to the specified torque. Tightening torque 7.8-10.8 N.m {79-111 kgf.cm, 69.0-95.6 in.lbf}

Scheme 19

Scheme 19: Air Hose Installation Note
Scheme 19: Air Hose Installation Note
  1. Align the alignment marks with the air hose notches.

INTAKE MANIFOLD REMOVAL/INSTALLATION

WARNINGFuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 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" when servicing the fuel system. (See BEFORE REPAIR PROCEDURE .) Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury. After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction. (See EPS SYSTEM NEUTRAL POSITION SETTING .)

Note. The engine must be removed to remove the intake manifold. Remove the engine, transmission, and crossmember component as a single unit downward of the vehicle.

Scheme 20

Scheme 20
Scheme 20
  1. Remove the following parts: The front wheel and tires. The engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).) The front suspension tower bar. (See «FRONT SUSPENSION TOWER BAR»(ref-170063-S10851823732004122800000).) The battery cover, battery, battery box and battery tray. The air cleaner, intake-air duct and air cleaner insulator. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).) The PCM. The AIR pump. (See «SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION»(ref-178415-S09881387372005061500000).)
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT»(ref-178321-S36202521982005061400000).)
  3. Disconnect the brake vacuum hose.
  4. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION»(ref-178411-S01806597482005061500000).)
  5. Disconnect the plastic fuel hose. (See «BEFORE REPAIR PROCEDURE»(ref-178411-S37662065742005061500000).)
  6. Remove the ignition coil. (See «IGNITION COIL REMOVAL/INSTALLATION»(ref-178175-S04050544232005061300000).)
  7. Remove the A/C belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165726).)
  8. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way.
  9. Disconnect the engine wiring harness from the main fuse block side.
  10. Remove the engine under cover.
  11. Disconnect front ABS wheel speed sensor connector. (See «FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION»(ref-178169-S15234392012005061200000).)
  12. Disconnect the radiator hose, the heater hose and coolant reserve tank hose.
  13. A/T Disconnect the selector link. (See «AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION»(ref-178192-S01223350732005061300000).) M/T Remove the clutch release cylinder with the pipes connected and secure the clutch release cylinder using wire or rope so that it is out of the way. (See «CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION»(ref-178194-S26259933992005061300000).) Remove the shift lever component. (See «AUTOMATIC TRANSMISSION SHIFT MECHANISM»(ref-178210).)
  14. Remove the engine, transmission, and crossmember component. (See «ENGINE REMOVAL/INSTALLATION»(ref-178318-S20337888982005061400000).)
  15. Remove the extension manifold (upper and lower). (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).)
  16. Remove the AIR control valve. (See «SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION»(ref-178415-S40450229912005061500000).)
  17. Remove in the order indicated. (Scheme 20)
  18. Install in the reverse order of removal.

Scheme 21

Scheme 21: Intake Manifold Installation Note
Scheme 21: Intake Manifold Installation Note

Scheme 22

Scheme 22
Scheme 22
  1. Apply oil thoroughly to the APVs (13B-MSP (HIGH POWER) as shown in the figure.
  2. Tighten the bolts in the order shown in the figure. (Scheme 22)
  3. Retighten the No. 1 bolt after tighten the all bolts. Tightening torque 18.6-25.5 N.m {1.8-2.6 kgf.m, 13.7-18.9 ft.lbf}

Scheme 23

Scheme 23: INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY
Scheme 23: INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY
  1. Remove in the order indicated. (Scheme 23)
  2. Install in the reverse order of removal.

Scheme 24

Scheme 24: VDI Valve Assembly Note
Scheme 24: VDI Valve Assembly Note
  1. Apply grease to the VDI valve end as shown in the figure.

Scheme 25

Scheme 25: VARIABLE FRESH AIR DUCT (VFAD) SOLENOID VALVE INSPECTION (13B-MSP (HIGH POWER))
Scheme 25: VARIABLE FRESH AIR DUCT (VFAD) SOLENOID VALVE INSPECTION (13B-MSP (HIGH POWER))

Scheme 26

Scheme 26
Scheme 26
  1. Disconnect the negative battery cable.
  2. Remove the VFAD solenoid valve. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).)
  3. Inspect for airflow. (Scheme 26) If it is normal, inspect related wiring harnesses. If there is any malfunction, replace the VFAD solenoid valve. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).)

Scheme 27

Scheme 27: Circuit Open/Short Inspection
Scheme 27: Circuit Open/Short Inspection
  1. Disconnect the PCM connector.
  2. Inspect the following wiring harness for open or short (continuity check).

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