Mazda 2: Intake-air System

INTAKE-AIR SYSTEM LOCATION INDEX

Mazda 2. INTAKE-AIR SYSTEM

  1. Air cleaner
    • (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION)
    • (SeeAIR CLEANER ELEMENT INSPECTION)
  2. Variable tumble shutter valve actuator
    • (See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION)
    • (SeeVARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION)
  3. Accelerator pedal
    • (See ACCELERATOR PEDAL REMOVAL/INSTALLATION)
  4. Air hose
    • (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION)
  5. Resonance chamber
    • (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION)
  6. Fresh-air duct
    • (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION)
  7. Throttle body
    • (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION)
    • (See THROTTLE BODY INSPECTION)
  8. Intake manifold
    • (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION)
    • (See INTAKE MANIFOLD VACUUM INSPECTION)

INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM

Mazda 2. INTAKE-AIR SYSTEM

INTAKE-AIR SYSTEM DIAGRAM

Mazda 2. INTAKE-AIR SYSTEM

INTAKE MANIFOLD VACUUM INSPECTION

1. Remove the fresh-air duct and the air cleaner case as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).

2. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (purge solenoid valve side) and install the vacuum gauge.

3. Install the fresh-air duct and the air cleaner case as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).

4. Verify that the intake air hoses are installed securely.

5. Warm up the engine.

6. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge.

Standard

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

WARNING:

CAUTION:

1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION).

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

3. Disconnect the wiring harness.

4. Remove in the order indicated in the table.

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

6. Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION).

7. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION).

8. Install in the reverse order of removal.

9. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION).

Mazda 2. INTAKE-AIR SYSTEM

  1. Fresh-air duct
  2. PCM connector cover
  3. PCM connector
  4. Air cleaner cover
  5. Air cleaner element
  6. Air cleaner case
  7. Ventilation hose (air hose side)
  8. Air hose
  9. Throttle body
  10. Evaporative hose (to purge solenoid valve)
  11. Vacuum hose (to master back)
  12. PCV hose (intake manifold side)
  13. Intake manifold

Air Cleaner Cover Removal Note

1. Remove the MAF/IAT sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION).

2. Remove the air cleaner cover.

Air Hose Removal Note

1. Move the purge solenoid valve slightly out of the way without removing the air hose.

Throttle Body Removal Note

WARNING:

CAUTION:

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 fuel distributor and fuel injector as a single unit. (See FUEL INJECTOR REMOVAL/INSTALLATION).

2. Remove the EGR pipe (intake manifold side). (See EGR PIPE REMOVAL/INSTALLATION).

3. Remove the MAP sensor. (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION).

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

5. Remove the intake manifold.

Throttle Body Installation Note

1. Install the throttle body to the intake manifold.

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

PCM Connector Connection Note

CAUTION:

Mazda 2. INTAKE-AIR SYSTEM

1. Verify that the PCM connector lever is tilted towards the wiring harness side as shown in the figure.

Mazda 2. INTAKE-AIR SYSTEM

2. Insert the PCM connector straight until it contacts the PCM and verify that the lever reverts upward naturally.

3. Push the lever until a click is heard.

Mazda 2. INTAKE-AIR SYSTEM

AIR CLEANER ELEMENT INSPECTION

1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).

2. Inspect the following items:

THROTTLE BODY INSPECTION

Resistance Inspection

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

2. Disconnect the throttle body connector.

3. Measure the resistance between throttle valve actuator terminals A and B.

Mazda 2. THROTTLE BODY INSPECTION

Specification

Mazda 2. THROTTLE BODY INSPECTION

VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION

Operation Inspection

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

2. Remove the variable tumble shutter valve actuator. (See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION).

3. Connect the battery positive voltage to terminal B or D, and verify that the gear moves.

Mazda 2. VARIABLE TUMBLE SHUTTER VALVE ACTUATOR

Mazda 2. VARIABLE TUMBLE SHUTTER VALVE ACTUATOR

VARIABLE TUMBLE SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION

CAUTION:

Mazda 2. VARIABLE TUMBLE SHUTTER VALVE ACTUATOR

  • Do not allow foreign material to contact the intake manifold side gear.
  • Keep the inside of the actuator away from foreign material.

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

2. Remove the fresh-air duct and air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).

3. Remove the battery. (See BATTERY REMOVAL/INSTALLATION).

4. Disconnect the variable tumble shutter valve actuator connector.

5. Remove in the order indicated in the table.

Mazda 2. VARIABLE TUMBLE SHUTTER VALVE ACTUATOR

  1. Variable tumble shutter valve actuator
  2. Retainer

6. Install in the reverse order of removal.

Variable Tumble Shutter Valve Actuator Removal Note

1. After removing the actuator, cover it with a plastic sheet to prevent foreign material from entering the inside of the actuator.

Retainer Removal Note

1. After removing the retainer, cover it with a plastic sheet to prevent foreign material from contacting the intake manifold side gear.

Retainer Installation Note

1. Install the retainer by positioning the projection on the intake manifold with the indentation on the retainer.

Mazda 2. VARIABLE TUMBLE SHUTTER VALVE ACTUATOR

2. Be careful not to shift the retainer installation position.

Variable Tumble Shutter Valve Actuator Installation Note

1. Verify that the retainer installation position has not shifted.

2. Verify that the gasket is installed.

3. Install the variable tumble shutter valve actuator.

4. Verify that intake manifold side gear and actuator side gear are engaged properly so that the actuator can be installed without any excessive force.

ACCELERATOR PEDAL REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION).

2. Remove in the order indicated in the table.

Mazda 2. ACCELERATOR PEDAL REMOVAL/INSTALLATION

  1. APP sensor connector
  2. Accelerator pedal

3. Install in the reverse order of removal.

READ NEXT:

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