Mazda CX 7. Manual - part 117

INTAKE-AIR SYSTEM [L3 WITH TC]

01-13–7

01-13

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. (See01-12-5 ENGINE COOLANT

REPLACEMENT[L3 WITH TC].)

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. (See01-11-6 OIL

PAN REMOVAL/INSTALLATION[L3 WITH TC].)

8. Remove the splash shield (RF).
9. Remove the drive belt. (See01-10-3 DRIVE BELT

REMOVAL/INSTALLATION[L3 WITH TC].)

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.

MAF/IAT sensor

Fresh air duct

Air cleaner cover

Air cleaner element

Air cleaner case

Resonance chamber
(See01-13-7 Air Hose Removal Note.)

Charge air cooler cover

Charge air cooler

Air bypass valve

Air hose
(See01-13-7 Air Hose Removal Note.)

Air duct (See 01-13-7 Air Duct Removal Note)

Throttle body
(See01-13-7 Throttle Body Removal Note.)
(See01-13-10 Throttle Body Installation Note.)

Vacuum chamber

Variable swirl solenoid valve

Intake manifold
(See01-13-7 Intake Manifold Removal Note.)

Wastegate control solenoid valve
(See01-13-10 Wastegate Control Solenoid Valve
Installation Note.)

Turbocharger
(See01-13-8 Turbocharger Removal Note.)
(See01-13-9 Turbocharger Installation Note.)

FUEL DELIVERY
PIPE COVER

acxuuw00000206

1871-1U-06B(01-13).fm 7 ページ２００６年３月１５日　水曜日　午前１０時４４分

INTAKE-AIR SYSTEM [L3 WITH TC]

01-13–8

Turbocharger Removal Note

1. Remove the middle pipe (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Disconnect the rear HO2S connector.
3. Remove the front pipe. (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)

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. (See09-16-11 COWL GRILLE REMOVAL/INSTALLATION.)
5. Remove the windshield wiper motor.
6. Remove the cowl panel.
7. Remove the insulator (Exhaust manifold upper side). (See01-15-2 EXHAUST SYSTEM REMOVAL/

INSTALLATION[L3 WITH TC].)

8. Set the generator out of the way. (See01-17-4 GENERATOR REMOVAL/INSTALLATION[L3 WITH TC].)
9. Remove the insulator (Exhaust manifold lower side). (See01-15-2 EXHAUST SYSTEM REMOVAL/

INSTALLATION[L3 WITH TC].)

10. Disconnect the front HO2S connector.
11. Remove the insulator (WU-TWC top side). (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3

WITH TC].)

12. Remove the vacuum hose (Brake master back side).
13. Remove the front HO2S. (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
14. Remove the WU-TWC. (See01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
15. Remove the oil pipes.

16. Remove the turbocharger.

OIL PIPE

acxuuw00000207

acxuuw00000285

1871-1U-06B(01-13).fm 8 ページ２００６年３月１５日　水曜日　午前１０時４４分

INTAKE-AIR SYSTEM [L3 WITH TC]

01-13–9

01-13

Turbocharger Installation Note

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. (See01-15-2 EXHAUST

SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)

3. Install the front HO2S. (See01-15-2 EXHAUST

SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)

4. Tight the oil pipe installation bolt while the stopper

of the oil pipe is faced to the turbocharger.

5. Install the oil pipes and, insert the oil hose until it

reaches the stopper.

38—51 N·m
{3.9—5.2 kgf·m,
29—37 ft·lbf}

acxuuw00000208

STOPPER

23.5—35.3 N·m
{2.40—3.59 kgf·m,
17.4—26.0 ft·lbf}

7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}

acxuuw00000209

STOPPER

OIL HOSE

7.8—10.8
{80—110, 70—95}

23.5—35.3 N·m
{2.40—3.59 kgf·m,
17.4—26.0 ft·lbf}

N·m {kgf·cm, in·lbf}

7.8—10.8 {80—110, 70—95}

acxuuw00000210

1871-1U-06B(01-13).fm 9 ページ２００６年３月１５日　水曜日　午前１０時４４分

INTAKE-AIR SYSTEM [L3 WITH TC]

01-13–10

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.

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

Caution

• Before 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.

7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}

WASTEGATE
CONTROL
SOLENOID
VALVE

1—4 mm
{0.04—0.15 in}

1—3 mm
{0.04—0.11 in}

DETAIL A

DETAIL B

(36˚)

(95˚)

(190˚)

acxuuw00000211

729)4,

acxuuw00000284

1871-1U-06B(01-13).fm 10 ページ２００６年３月１５日　水曜日　午前１０時４４分

Content .. 115 116 117 118 ..