Fuel Delivery and Air Induction: Service and Repair

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5]

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".

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

2. Remove the battery cover. Removal and Replacement

3. Disconnect the negative battery cable. Removal and Replacement

4. Remove the plug hole plate. Service and Repair

5. Disconnect the wiring harness.

6. Remove in the order indicated in the table.

7. Install in the reverse order of removal.

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

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

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

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

Step 1










Step 2










Air Cleaner Cover Removal Note

1. Remove the air cleaner cover and resonance chamber and air hose as a single unit.

2. Remove the air cleaner cover.

Fresh-Air Duct (No.1) Removal Note

1. Remove the fresh-air duct (No.1) and fresh-air duct (No.2) as a single unit.

2. Remove the fresh-air duct (No.1).

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 aerodynamic under cover. Service and Repair

2. Put the cooling system filler neck out of the way of work with its hose connected.

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

4. Disconnect the vacuum hoses connecting the intake manifold.

5. Remove the fuel distributor. Service and Repair

6. Remove the intake manifold.

Throttle Body Installation Note

1. Temporarily tighten the throttle body to the intake manifold.

2. Tighten the installation bolts in the order shown in the figure.






Throttle body tightening torque
- 8-11 Nm {82-112 kgf-cm, 71-97 in-lbf}

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

Air Hose Installation Note

1. install the air hose as shown in the figure.