Mazda B-Series 1998-06

Intake Manifold

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Removal & Installation




WARNING
Anytime the upper or lower intake manifold has been removed, cover all openings with a rag or a sheet of plastic to prevent dirt and debris from falling into the engine.

2.3L Engine
  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. Properly discharge the A/C system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    The alternator will be removed with the accessory bracket.



    Negative battery cable
     
    Water outlet tube.
     
    Water outlet tube.
     



    Accessory bracket.
     
    Coolant hose from the thermostat.
     
    Coolant hose from the EGR valve.
     
    Coolant tube assembly.
     
    Block heater (if so equipped).
     
    Water outlet.
     
    EGR valve.
     
    Idle air control (IAC) valve.
     
    Throttle position (TP) sensor.
     
    Manifold absolute pressure (MAP) sensor.
     
    Swirl control valve monitor electrical connector.
     
    Electric thermostat.
     
    Swirl control valve.
     
    CMP sensor electrical connector and disconnect the PCV hose from the intake manifold.
     
    Engine wiring harness pin-type retainers from the intake manifold.
     
    Engine wiring harness connector bracket. Position the engine wiring harness aside.
     
    EGR tube.
     
    Fuel supply line clip from the front of the intake manifold. Disconnect the vacuum hose from the intake manifold.
     
    Intake manifold assembly.
     

  10.  
  11. Installation is the reverse of removal. Torque the bolts to 13 ft. lbs. (18Nm). There is no special torque sequence.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Remove the accelerator control snow shield. Remove the air cleaner outlet tube.
  8.  
  9. Disconnect the throttle cables from the intake manifold.
  10.  
  11. Disconnect the TP sensor. Disconnect the MAP sensor electrical connector.
  12.  
  13. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
  14.  
  15. Disconnect the engine vacuum harness and brake booster hose and the PCV breather hose.
  16.  
  17. Disconnect the engine wiring harness and position it to the side.
  18.  
  19. Remove the EGR (EEGR) tube bracket bolt. Disconnect the swirl control valve monitor electrical connector.
  20.  
  21. Disconnect the fuel line from the clip. Remove the bolts from the EEGR tube flange.
  22.  
  23. Detach the 42 pin electrical connector from the bracket and disconnect the intake vacuum hose.
  24.  
  25. Disconnect the KS sensor electrical connector and disconnect the connector from the intake manifold.
  26.  
  27. Remove the wiring harness push pin from the bottom of the intake manifold. Disconnect the fuel manifold vacuum hose.
  28.  
  29. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  30.  

To install:

  1. Be sure to clean all old gasketing material from the sealing surfaces, using the proper tools.
  2.  
  3. Installation is the reverse of the removal procedure.
  4.  
  5. Be sure to use new gaskets.
  6.  
  7. Torque the bolts to 13 ft. lbs. (18 Nm).
  8.  
  9. Start the engine and check for fuel leaks, correct as required.

    Click image to see an enlarged view

    Fig. Intake manifold bolts-2.3L engine

  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Remove the accelerator control splash shield. Remove the air cleaner outlet tube.
  8.  
  9. Disconnect the throttle cables from the intake manifold.
  10.  
  11. Disconnect the TP sensor. Disconnect the MAP sensor electrical connector.
  12.  
  13. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
  14.  
  15. Disconnect the engine vacuum harness and brake booster hose and the PCV breather hose.
  16.  
  17. Disconnect and plug the heater hoses.
  18.  
  19. Disconnect the two engine wiring harness pin type retainers from the intake manifold. Disconnect the pin type retainer from the rear of the intake manifold.
  20.  
  21. Remove the EGR (EEGR) tube bracket bolt. Disconnect the fuel hose from the clip. Remove the bolts from the EEGR tube flange.
  22.  
  23. Detach the 42 pin electrical connector from the bracket and disconnect the vapor purge hose.
  24.  
  25. Disconnect the KS sensor electrical connector and disconnect the connector from the intake manifold.
  26.  
  27. Remove the wiring harness push pin from the bottom of the intake manifold. Remove the bracket. Disconnect the fuel supply line from the manifold.
  28.  
  29. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.
  30.  

To install:

  1. Be sure to clean all old gasketing material from the sealing surfaces, using the proper tools.
  2.  
  3. Installation is the reverse of the removal procedure.
  4.  
  5. Be sure to use new gaskets.
  6.  
  7. Torque the bolts to 13 ft. lbs. (18 Nm).
  8.  
  9. Be sure to fill the cooling system with the proper grade and type engine coolant.
  10.  
  11. Start the engine and check for leaks, correct as required.
  12.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor
     
    Air cleaner outlet tube
     
    Accelerator control splash shield
     
    Engine control sensor wiring from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve
     
    Accelerator cable and speed control cable, if equipped
     
    Accelerator cable bracket
     
    Crankcase vent hose from the valve cover
     
    Vacuum hoses from the intake manifold vacuum tee
     
    Heater hose from the intake manifold
     
    Exhaust Gas Recirculation (EGR) tube
     
    EGR valve
     
    Upper intake manifold and discard the gasket
     

  4.  

To install:

  1. Install a new upper intake manifold gasket.

    Click image to see an enlarged view

    Fig. Tighten the lower manifold bolts in the sequence shown-2.5L engine



    Click image to see an enlarged view

    Fig. Tighten the upper manifold bolts in the sequence shown-2.5L engine

  2.  
  3. Install the upper intake manifold. Torque the bolts in sequence as follows:
    1. Step 1: 89 inch lbs. (10 Nm).
    2.  
    3. Step 2: 28 ft. lbs. (38 Nm).
    4.  

  4.  
  5. Install or connect the following:

    EGR valve. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    EGR valve tube. Torque the bolts to 34 ft. lbs. (47 Nm).
     
    Heater hoses to the intake manifold
     
    Vacuum hoses to the tee
     
    Crankcase vent hose to the valve cover
     
    Accelerator cable bracket. Torque the bolts to 20 ft. lbs. (28 Nm).
     
    Accelerator cable and speed control cable, if equipped
     
    IAC valve and TP sensor electrical connectors
     
    Air cleaner outlet tube
     
    IAT sensor
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks, repair if necessary.
  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor
     
    Air cleaner outlet tube
     
    Accelerator control splash shield
     
    Accelerator cable and speed control cable, if equipped
     
    Engine control sensor wiring from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve and Exhaust Gas Recirculation (EGR) transducer
     
    EGR tube from the valve
     
    EGR vacuum lines
     
    42 pin connector bracket
     
    Throttle body and gasket
     
    Ignition coil and move it aside
     
    Evaporative Emissions (EVAP) hose
     
    Upper intake manifold bolts and discard them
     
    Crankcase vent hose
     
    Upper intake manifold and discard the gasket
     

  4.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Install or connect the following:

    New upper intake manifold
     
    Intake manifold
     
    Crankcase vent hose

    Click image to see an enlarged view

    Fig. Tighten the lower manifold bolts in the sequence shown-3.0L engine

     

  4.  
  5. Torque the upper intake manifold bolts in sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm).
    2.  
    3. Step 2: 18 ft. lbs. (25 Nm).
    4.  

  6.  
  7. Install or connect the following:

    EVAP hose
     
    EGR tube
     
    EGR transducer. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Ignition coil. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    New gasket and throttle body. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    42 pin connector
     
    EGR vacuum lines
     
    EGR transducer, IAC valve and TP sensor electrical connectors
     
    Accelerator cable and speed control, if equipped
     
    Accelerator cable splash shield
     
    Air cleaner outlet tube
     
    IAT sensor
     
    Negative battery cable
     

  8.  
  9. Start the vehicle and check for leaks, repair if necessary.
  10.  

Lower Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove both the valve covers.
  10.  
  11. Disconnect the upper radiator hose, heater hose and coolant bypass hose.
  12.  
  13. Disconnect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.
  14.  
  15. Disconnect the crankshaft position (CKP) sensor and detach the wiring from the stud bolt.
  16.  
  17. Disconnect the fuel injector electrical connectors and position the engine control wiring aside.
  18.  
  19. Disconnect the fuel tube.
  20.  
  21. Loosen the rocker arm bolts.
    NOTE
    Identify the location of each pushrod. Each pushrod is to be installed in the original location to prevent premature wear.

  22.  
  23. Remove all the pushrods.
  24.  
  25. Remove the bolts from the lower intake manifold.
    NOTE
    Gently loosen the intake manifold to separate the silicone sealant from the cylinder block.

  26.  
  27. Remove the lower intake manifold.
  28.  
  29. Remove and discard the intake manifold gaskets and end seals.
  30.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-3.0L engine


NOTE
Clean and inspect all mating surfaces.


NOTE
If the lower intake manifold is not installed within four minutes, remove the sealant and reapply.

  1. Apply a drop of silicone gasket and sealant at the four cylinder block-to-cylinder head seams.
  2.  
  3. Install the intake manifold gaskets and end seals.
  4.  
  5. Position the lower intake manifold.
  6.  
  7. Install the bolts and tighten in the sequence shown to 21 ft. lbs. (29 Nm).
  8.  
  9. Install the pushrods.
  10.  
  11. Tighten the rocker arms to 24 ft. lbs. (32 Nm).
  12.  
  13. Connect the fuel tube.
  14.  
  15. Connect the fuel injector electrical connectors.
  16.  
  17. Connect the crankshaft position (CKP) sensor and attach the wiring from the stud bolt.
  18.  
  19. Connect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.
  20.  
  21. Connect the upper radiator hose, heater hose and coolant bypass hose.
  22.  
  23. Install both valve covers.
  24.  
  25. Fill and bleed the engine cooling system.
  26.  

Upper Manifold


Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-3.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Remove the air cleaner outlet pipe.
  6.  
  7. Remove the bolt and the snow shield.
  8.  
  9. Disconnect the accelerator cable, speed control cable and the return spring.
  10.  
  11. Disconnect the accelerator cable and speed control cable from the accelerator bracket.
  12.  
  13. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
  14.  
  15. Disconnect the two vacuum hoses.
  16.  
  17. Detach the 42-pin wiring harness retainer from the stud bolt.
  18.  
  19. Remove the nut and the stud bolt. Position the 42-pin wiring harness and bracket aside.
  20.  
  21. Remove the oil indicator tube bracket nut and the upper intake manifold support bracket stud bolt.
  22.  
  23. Disconnect the brake booster vacuum hose and the positive crankcase ventilation (PCV) valve tube.
  24.  
  25. Remove the bolts, the stud bolt and the upper intake manifold. Remove and discard the gaskets.
  26.  

To install:

  1. Be sure to clean all old gasketing material from the sealing surfaces, using the proper tools.
  2.  
  3. Installation is the reverse of the removal procedure.
  4.  
  5. Be sure to use new gaskets.
  6.  
  7. Torque the bolts to 89 inch lbs. (10 Nm).
  8.  

4.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Remove the bolts and the shield.
  6.  
  7. Remove the air cleaner outlet pipe.
  8.  
  9. Disconnect the idle air control (IAC) valve, throttle position (TP) sensor electrical connectors and the TP sensor wiring pin-type retainer.
  10.  
  11. Disconnect the MAF sensor wiring pin-type retainer.
  12.  
  13. Detach the accelerator and speed control cables from the throttle body.
  14.  
  15. Detach the accelerator and speed control cables from the bracket, and position the cables aside.
  16.  
  17. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.
  18.  
  19. Disconnect the EGR vacuum regulator solenoid valve electrical connector and vacuum hose.
  20.  
  21. Disconnect the hose.
  22.  
  23. Loosen the clamp and disconnect the brake booster vacuum hose.
    CAUTION
    It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.


    NOTE
    Mark the spark plug wire locations before removing them.

  24.  
  25. Disconnect the RH spark plug wires from the coil. Remove the spark plug wire routing clip pin-type retainer and position the wires aside.
  26.  
  27. Remove the wiring harness bracket retainer, then position the wiring harness aside.
  28.  
  29. Remove the accelerator cable routing clip pin-type retainer and the wiring harness pin-type retainer.
  30.  
  31. Remove the bolts.
  32.  
  33. Remove the bolts and position the coil and bracket aside.
  34.  
  35. Disconnect the vacuum hoses.
  36.  
  37. Remove the nut.
  38.  
  39. Disconnect the powertrain control module (PCM) electrical connector.
  40.  
  41. Remove the retainer and position the ground wires aside.
  42.  
  43. Detach the electrical connector retainer.
  44.  
  45. Remove the intake manifold bolts and lift up the intake manifold.
  46.  
  47. Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.
  48.  
  49. Remove the intake manifold retaining bolts. Remove the intake manifold from the engine.

    Click image to see an enlarged view

    Fig. Intake manifold installation-4.0L engine

  50.  

To install:

  1. Be sure to clean all old gasketing material from the sealing surfaces, using the proper tools.
  2.  
  3. Installation is the reverse of the removal procedure.
  4.  
  5. Be sure to use new gaskets.
  6.  
  7. Torque the bolts to 89 inch lbs. (10 Nm).
  8.  

OHV Engine

The intake manifold is a 4-piece assembly, consisting of the upper intake manifold, the throttle body, the fuel supply manifold, and the lower intake manifold.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner outlet tube
     
    Accelerator cable splash shield
     
    Spark plug wires from the ignition coil
     
    Ignition coil and radio interference capacitor electrical connectors
     
    Throttle Position (TP) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Canister purge line from the throttle body
     
    Fuel line bracket
     
    Upper intake manifold and discard the gasket
     

  4.  

To install:

Click image to see an enlarged view

Fig. Tighten the manifold bolts in the sequence shown-4.0L OHV engine

  1. Install or connect the following:

    New gasket and the upper manifold. Torque the nuts to 18 ft. lbs. (25 Nm).
     
    Fuel line bracket
     
    Canister purge line to the throttle body
     
    Brake booster vacuum hose
     
    IAC valve electrical connector
     
    TP sensor electrical connector
     
    Ignition coil and radio interference capacitor electrical connectors
     
    Spark plug wires to the proper spark plug
     
    Accelerator cable and speed control cable, if equipped
     
    Accelerator cable splash shield
     
    Air cleaner outlet tube
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

SOHC Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner-to-intake tube
     
    Accelerator splash shield
     
    Accelerator and, if equipped with cruise control, speed control cables from the throttle control cam
     
    Accelerator cable retaining bracket from the upper intake manifold
     
    Label and disengage all vacuum and electrical connections on the intake manifold.
     
    Upper intake manifold attaching bolts
     
    Lift up on the manifold and remove both fuel Vapor Management Valve (VMV) hoses
     
    Upper intake manifold and discard the gasket
     

  4.  

To install:


NOTE
Ford does not specify a sequence for either upper or lower intake manifolds, but it is recommended that you start tightening in the middle and work your way out to the ends. Repeat the tightening sequence several times until the bolts will no longer turn at the specified torque.

  1. Position the upper manifold on the lower manifold.
  2.  
  3. Install or connect the following:

    Attach both VMV hoses to the manifold
     
    Upper manifold attaching bolts. Torque the bolts to 62 inch lbs. (7 Nm).
     
    Attach any vacuum and electrical connections that were removed
     
    Accelerator cable bracket to the intake and the cable (or cables if equipped with cruise control) to the throttle cam
     
    Accelerator splash shield
     
    Air cleaner-to-intake supply tube
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

 
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