Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Intake Manifold

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REMOVAL & INSTALLATION



Carbureted Engine
  1. Remove the air cleaner assembly. Disconnect the carburetor linkage. Drain the radiator.
  2.  
  3. Tag and disconnect all vacuum hoses and fuel lines from the carburetor (plug the fuel lines to prevent leakage).
  4.  
  5. Tag and disconnect all carburetor wiring.
  6.  
  7. Disconnect and remove the air pump.
  8.  
  9. Disconnect the metering oil pump connecting rod and hoses.
  10.  
  11. Remove the air outlet pipe from the end of the manifold. Disconnect the vacuum sensing tube.
  12.  
  13. Remove the exhaust manifold cover, then unbolt and remove the inlet manifold, complete with the carburetor.
  14.  
  15. Remove the gasket and O-rings. Thoroughly clean the mating surfaces.
  16.  

To install:
  1. Position a new gasket and O-rings.
  2.  
  3. Position the inlet manifold and install its retaining bolts. Torque the bolts to 14-19 ft. lbs. (19-26 Nm).
  4.  
  5. Install the exhaust manifold cover.
  6.  
  7. Connect the air outlet pipe and the vacuum sensing tube.
  8.  
  9. Attach the metering oil pump connecting rod and hoses.
  10.  
  11. Install the air pump.
  12.  
  13. Connect the carbureter wiring.
  14.  
  15. Connect the fuel lines and applicable vacuum hoses.
  16.  
  17. Fasten the carbureter linkage, then install the air cleaner assembly.
  18.  
  19. Fill the cooling system to the proper level with a suitable coolant mixture.
  20.  

Fuel Injected Engine
NON-TURBO
  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Remove the air funnel and disconnect the accelerator cable.
  4.  
  5. Disconnect the cruise control cable, if equipped.
  6.  
  7. Disconnect the throttle sensor connector.
  8.  
  9. Disconnect the metering pump oil rod.
  10.  
  11. Label then remove the water, fuel and vacuum hoses. Plug the fuel hose openings.
  12.  
  13. If so equipped, disconnect the air supply valve (1985) or bypass air control valve (1986-89).
  14.  
  15. Unfasten the air intake temperature sensor connector.
  16.  
  17. Remove the nuts and bolts, then lift the dynamic chamber from the engine. Remove the gasket and cover the intake ports with a clean rag to prevent anything from falling into the engine. Thoroughly clean all gasket mating surfaces and inspect the chamber for cracks or any other type of damage.
  18.  

To install:
  1. Place a new gasket onto the lower chamber flange, then install the chamber and attaching hardware.
  2.  
  3. Connect the intake air temperature sensor.
  4.  
  5. If applicable, connect the bypass air control valve or air supply valve.
  6.  
  7. Connect the vacuum, fuel and water hoses.
  8.  
  9. Connect the metering oil pump rod.
  10.  
  11. Fasten the throttle sensor connector.
  12.  
  13. Connect the cruise control (if so equipped) and accelerator cables.
  14.  
  15. Install the air funnel and connect the negative battery cable.
  16.  

TURBO
  1. Disconnect the negative battery cable and drain the cooling system.
  2.  
  3. Disconnect the inlet and outlet hoses, then remove the intercooler.
  4.  
  5. Unbolt and remove the oil filler pipe with the gasket. Immediately cover the oil filler opening to prevent anything from falling into the engine.
  6.  
  7. Disconnect the accelerator cable from the throttle body.
  8.  
  9. Disconnect the cruise control cable, if so equipped.
  10.  
  11. Disconnect the metering pump oil rod.
  12.  
  13. Tag and disconnect all electrical connectors from the throttle body.
  14.  
  15. Disconnect the vacuum tubes and water hoses.
  16.  
  17. Remove the nuts and bolts, then lift the dynamic chamber from the engine. Remove the gasket and cover the intake ports with a clean rag to prevent anything from falling into the engine. Thoroughly clean all gasket mating surfaces and inspect the chamber for cracks or any other type of damage.
  18.  

To install:
  1. Place a new gasket onto the lower chamber flange studs, then install the chamber with the nuts and bolts.
  2.  
  3. Connect the water hoses and vacuum tubes.
  4.  
  5. Connect the throttle body electrical connectors.
  6.  
  7. Connect the metering pump oil rod.
  8.  
  9. Connect the cruise control cable, if so equipped.
  10.  
  11. Connect the accelerator cable.
  12.  
  13. Inspect the oil filler pipe flange gasket for rips or tears. If in good condition, reuse it. Install the oil filler pipe with its attaching bolts.
  14.  
  15. Install the intercooler, then connect the inlet and outlet hoses.
  16.  
  17. Fill the cooling system to the proper level with a suitable coolant mixture.
  18.  
  19. Connect the negative battery cable. Start the engine and inspect for leaks.
  20.  

 
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