Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Engine vibration, rpm fluctuations at idle, or poor accelerator response along with codes P2020 (P0172), P2046, P201C or P201A may be caused by a tear in the partial load vent hose at the connection to the crankcase. Air will bypass the mass air sensor — i.e. unmeasured air will enter the intake — causing the engine to run lean. The remedy: 1. Remove the supercharger. Refer to WIS document AR09.50-P-4705QK. 2.Remove and install partial load vent hose for crankcase ventilation. 3.Install the supercharger according to the WIS document above. Note: Use a “click clamp” as specified in parts information for securing hose. Ensure that the clamp is positioned as close to the end of the hose as possible and fastened tight. Parts Information: Click Clamp, 005 997 49 90 Partial Load Vent Hose, 271 018 04 82

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Removal of Factory Intake 1. 2. Pull upwards to remove the engine cover. Unclip the battery cover and remove, then disconnect the negative battery cable. Disengage the plastic rivet. Slide the battery cold air vent backwards and remove from the engine compartment. Disconnect the mass air sensor electrical connection. Depress the retaining clip and disconnect the rank case vent hose from the stock intake tube. Remove the switch/sensor from the air cleaner cover. Loosen the clamp at the throttle body. Unclip the coolant hose from the air cleaner cover. Unclip the air cleaner cover and remove the complete upper air cleaner assembly. Remove the rubber retainer from the core support. Remove the lower air cleaner assembly. Unclip the wire harness from the side of the battery box. Remove the mass air sensor from the air cleaner cover. Remove the plastic clip from the crank case vent on the stock intake tube. Slide the clamps off rubber rank case vent. Remove the plastic vent from the stock intake tube. Slide the plastic clip from before back onto the crank case vent. Raise the vehicle up and support by jack stands, then remove the left front tire. Remove the four bolts and one plastic rivet from the inner valance, then remove the valance. Remove the three plastic rivets and six hex bolts on the inner valance, then pull the inner valance downward. Remove the three bolts that secure the air intake resonator to the inner fender, then remove the resonator. Secure the rubber mounted stud to the hole on the battery tray. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Install of Intake 24. Install reducer and clamps onto the throttle body. 25. Install the hose onto the vent on the intake tube. 26. Install the mass air sensor into the intake tube. 27. Slide the tube into the reducer and line up the bracket with stud, then tighten the clamps at the throttle body. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Secure the switch to the bracket (not for the 06 Mazda 5 model). Install the crank case vent into the hose on the intake tube. Reconnect the crank case vent. Install the rubber mounting stud into the resonator threaded hole. Install the reducer and clamps onto the cold air tube. From underneath the vehicle install the cold air tube. Slide the cold air tube onto the short ram tube. Secure the bracket to the tuber mounted stud. Install the filter onto the cold air tube from the underneath vehicle. Reconnect the mass air sensor. Reverse the removal process and reinstall the inner fender valance. Reinstall the front tire and torque to factory specs. Slide the vent into the core support and line up the other end with the battery box and secure with plastic rivet. 41. Reconnect the negative battery cable, then reinstall the battery cover. 42. Reinstall the engine cover. Resetting the ECU This is to be completed at your own risk. This procedure will reset the computer so that it may “learn” of your new intake. We are not to be held liable for any mishaps that you may occur while completing this process. • • Disconnect the Negative battery cable for 5 minutes. Reconnect the battery cable and false panel cover.

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1. Remove the battery and the battery tray. For additional information, refer to Section 414-01. 2. Disconnect the breather tube and mass air flow (MAF) sensor. 3. Remove the intake tube and air cleaner cover. 4. Remove the air cleaner assembly. 5. Disconnect the transmission range (TR) sensor. 6. Disconnect the HO2S sensor. 7. Disconnect the transaxle harness connector and remove the wire harness bracket nut. 8. Position the wire harness bracket out of the way. 9. Disconnect the vent hose from transmission filler tube bracket. 10. Unclip the wire harness. 11. Disconnect the shift cable. 12. Disconnect the wire harness from the shift cable bracket to gain access to the bracket bolts. 13. Remove the shift cable and bracket, and position out of the way. 14. Disconnect the starter motor harness connector. 15. Disconnect the ground wire. 16. Remove two starter bolts, and remove the starter motor. 17. Install the special tools. 18. Remove both electrical connectors from the upper intake to gain access to the engine lifting bracket.

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1. Drain the fuel tank (9002); refer to Section 310-00 . 2. Remove the front two fuel tank skid plate bolts. 3. Remove the rear LH bolt. 4. Remove the rear RH bolt and lower the fuel tank skid plate. 5. Use a suitable jack to support the fuel tank. 6. Remove the (A) fuel tank filler pipe (9034) and the (B) vent hose. 7. Remove the fuel tank support strap bolt and remove the fuel tank support strap (9092). 8. Remove the two fuel tank support bracket bolts and push the fuel tank back until the lip clears the support bracket. 9. Lower the fuel tank just enough to expose the fuel lines and the fuel tank transducer connector. 10. Disconnect the fuel lines; refer to Section 310-00 . 11. Disconnect the fuel tank pressure transducer electrical connector and lower the fuel tank. Installation 1. Connect the fuel tank pressure transducer electrical connector. 2. Connect the fuel lines; refer to Section 310-00 . 3. Raise the fuel tank into position, slide it forward into the support bracket, and install the two fuel tank support bracket bolts. 4. Position the fuel tank support strap and install the bolt.

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WORK PROCEDURE A. FUEL TANK REMOVAL CAUTION: DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM. 1. PLACE THE VEHICLE ON A LIFT 2. RECORD AUDIO STATION PRESETS 3. RELEASE FUEL SYSTEM PRESSURE (a) Remove the circuit opening relay from the engine room relay block. (b) Start engine and run it until it stops. NOTE: It is possible that DTC P0171 (system too lean) may be set during the above operation. Negative Terminal 4. CONFIRM THAT THE IGNITION SWITCH IS IN THE LOCK POSITION 5. DISCONNECT THE NEGATIVE BATTERY TERMINAL 6. REINSTALL THE CIRCUIT OPENING RELAY 7. DRAIN THE TANK USING THE FUEL STORAGE CART 8. REMOVE THE CHARCOAL CANISTER PROTECTOR (a) Remove the 6 bolts. (b) Remove the charcoal canister protector. 9. REMOVE THE FUEL TANK FILLER HOSE COVER (a) Remove the 3 bolts. (b) Remove the filler hose cover. 10. REMOVE THE FUEL TANK ASSEMBLY (a) Disconnect the fuel tank vent hose. 1. Push the connector into the canister to release the lock tab. 2. Pinch portion A. 3. Remove the connector. (b) Disconnect the fuel tank main tube. 1. Pinch the tube connector. 2. Remove the main tube. NOTE: Prior to removal, clean any dirt around the connector. Do not damage the “O-Rings” that seal the pipe and connector. Do not use any tools to release the tube. Do not bend or twist the nylon tube. Cover the connector in a plastic bag to prevent contamination. If the pipe and connector are stuck, carefully push and pull the connector to release and gently pull the connector out.