626 1999-2001

Intake Manifold

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Removal & Installation



2.0L (Fs) Engine

Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct and air cleaner assembly
     
    Mass Air Flow (MAF) sensor
     
    Air hose
     
    Accelerator cable
     
    Throttle body assembly
     
    Idle Air Control (IAC) valve
     
    Intake manifold stay
     
    Intake manifold and discard the gasket
     

  8.  
  9. Clean the mating surfaces of any gasket material

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly-626 with 2.0L (FS) engine

  10.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Make certain that the convex side of the new gasket faces the intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Intake manifold stay
     
    IAC valve. Torque the bolt to 39-57 inch lbs. (4-6 Nm).
     
    Throttle body. Torque the nuts to 18 ft. lbs. (25 Nm).
     

  2.  
  3. When connecting the accelerator cable, perform the following adjustment:
    1. Move the white locking tab to the unlock position.
    2.  
    3. Turn stopper B to the to the unlock position.
      NOTE
      If stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

    4.  
    5. Push or pull the cable housing directly behind the spring.
    6.  
    7. Turn the stopper B to the lock position.
    8.  
    9. Measure the free play which should be 0.06-0.15 inch (1.5-4mm) and make sure the cable free play is within specification.
    10.  
    11. Move the white locking tab to the lock position and check for proper accelerator operation.

      Click image to see an enlarged view

      Fig. Accelerator cable adjustment components-626 and Protégé models equipped with the 2.0L (FS) engine

    12.  

  4.  
  5. Install or connect the following:

    Air hose
     
    MAF sensor. Torque the bolt to 95 inch lbs. (11 Nm).
     
    Air cleaner/air duct assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

2.0L Engine

Specific to:

Mazda 626 1999-2000

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct and air cleaner assembly
     
    Mass Air Flow (MAF) sensor
     
    Accelerator cable
     
    Throttle body assembly
     
    Idle Air Control (IAC) valve
     
    Intake manifold stay
     
    Fuel rail
     
    Vent pipe
     
    Variable Resonance Induction System (VRIS) check valve
     
    Intake manifold and discard the gasket
     

  8.  
  9. Clean the mating surfaces of any gasket material
  10.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Make certain that the convex side of the new gasket faces the intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    VRIS check valve. Torque the bolt to 89 inch lbs. (10 Nm)
     
    Vent pipe. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Intake manifold stay
     
    IAC valve. Torque the bolt to 18 ft. lbs. (25 Nm)
     
    Throttle body. Torque the nuts to 22 ft. lbs. (30 Nm)
     
    Accelerator cable
     
    MAF sensor. Torque the bolt to 89 inch lbs. (10 Nm)
     
    Air cleaner/air duct assembly. Torque the bolts to 30 inch lbs. (3.5 Nm)
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2.5L (Kl) Engine

Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct and air cleaner assembly
     
    Mass Air Flow (MAF) sensor
     
    Air hose
     
    Accelerator cable
     
    Throttle body assembly
     
    Idle Air Control (IAC) valve
     
    Intake manifold stay
     
    Intake manifold and discard the gasket
     

  8.  
  9. Clean the mating surfaces of any gasket material

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly-626 with 2.5L (KL) engine

  10.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Intake manifold stay
     
    IAC valve.
     
    Throttle body. Torque the nuts to 18 ft. lbs. (25 Nm).
     
    Accelerator cable
     
    Air hose
     
    MAF sensor. Torque the bolt to 95 inch lbs. (11 Nm).
     
    Air cleaner/air duct assembly
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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