Mazda Car 2002-04

Intake Manifold 2

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Removal & Installation



2.5L (Kl) 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. 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.  

  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
     
    Air hose
     
    Mass Air Flow (MAF) sensor
     
    Water hoses from the throttle body
     
    Throttle body assembly
     
    Accelerator cable
     
    Fuel hoses from the rail
     
    Pipe and harness, refer to the illustration for component location
     
    Exhaust Gas Recirculation (EGR) Valve
     
    EGR pipe
     
    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-Millenia 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).
     
    EGR pipe and valve
     
    Pipe and harness, refer to the illustration for component location
     
    Fuel hoses to the rail
     
    Accelerator cable
     
    Throttle body assembly
     
    Water hoses to the throttle body. Torque the nuts to 18 ft. lbs. (25 Nm).
     
    MAF sensor. Torque the bolt to 95 inch lbs. (11 Nm).
     
    Air hose
     
    Fresh air duct and air cleaner assembly
     
    Negative battery cable
     

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

2.5L Engine
  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
     
    Air cleaner assembly and ducts
     
    Accelerator cable
     
    Necessary electrical connectors and vacuum hoses
     
    Fuel lines
     
    Coolant hose from the air bypass valve
     
    Intake manifold support bracket
     
    Intake manifold-to-cylinder head bolts
     
    Intake manifold
     
    Throttle body and air intake pipe from the manifold, if necessary
     

  8.  
  9. Check the intake manifold for cracks or other damage. Check the surface of the cylinder heads and intake manifold for warpage using a straightedge. Replace the intake manifold, as necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly-2.5L engine

  10.  

To install:

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

    Throttle body using new gaskets, if removed. Torque the bolts to 19 ft. lbs. (25 Nm)
     
    Air intake pipe using a new O-rings lubricated with engine oil, if removed. Torque the bolts to 95 inch lbs. (10.8 Nm)
     
    Intake manifold using new gaskets. Tighten the bolts, in 2-3 steps, to 19 ft. lbs. (25 Nm), working from the center toward the ends of the manifold.
     
    Intake manifold bracket. Tighten the bolts to 19 ft. lbs. (25 Nm)
     
    Coolant hose to the air bypass valve
     
    Fuel lines
     
    Vacuum hoses and electrical connectors
     
    Accelerator cable
     
    Air cleaner assembly and ducts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks. Check the idle speed.
  8.  

3.0L Engine
AJ Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly and related components-Mazda6 with the 3.0L (AJ) engine

  1. Remove the left front mud guard and resonance chamber.
  2.  
  3. Remove the Mass Airflow (MAF) and Intake Air Temperature (IAT) sensors.
  4.  
  5. Remove the purge solenoid valve vacuum hose.
  6.  
  7. Remove the air hose.
  8.  
  9. Remove the water hose.
  10.  
  11. Remove the throttle body.
  12.  
  13. remove the upper radiator hose, disconnect the Exhaust Gas Recirculation (EGR) pipe, EGR electrical connector and valve.
  14.  
  15. Remove the dynamic chamber bolts, chamber and gasket and discard the gasket.
  16.  
  17. Remove the fuel rail and injectors as an assembly.
  18.  
  19. Remove the intake manifold bolts, the manifold and gasket.
  20.  
  21. Discard the gasket.
  22.  
  23. Clean the mating surfaces of any gasket material.
  24.  

To install:

  1. Installation is the reverse of removal, please note the following:
    1. Install a new gasket and the manifold. Tighten the manifold bolts in the sequence illustrated to 72-106 inch lbs. (8-12 Nm).
    2.  
    3. Install a new dynamic chamber gasket and the chamber. Tighten the bolts in the sequence illustrated to 72-106 inch lbs. (8-12 Nm).
    4.  
    5. Install the EGR valve and tighten the retainers to the specifications shown in the accompanying illustration.
    6.  
    7. Connect the EGR connector, and pipe.

      Click image to see an enlarged view

      Fig. Tighten the lower intake manifold bolts in this sequence-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Tighten the dynamic chamber bolts in this sequence-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Exploded view of the EGR assembly mounting and components-Mazda6 with the 3.0L (AJ) engine

    8.  

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks as follows:
    1. Using a jumper wire, short the check connector to terminal F/P to a body ground.

      Click image to see an enlarged view

      Fig. Using a jumper wire, short the check connector to terminal F/P to a body ground-Mazda6 models

    2.  
    3. Turn the ignition switch the ON position to activate the fuel pump.
    4.  
    5. Check the hoses, clips and other fuel system components for leaks.
    6.  
    7. If there are any leaks, replace the fuel hoses and clips. If the is damage to the seal on the fuel pipe side, replace the pipe.
    8.  
    9. The system must be leak free for five minutes with the terminal grounded. If any component is replaced because of a system, leak, turn the ignition key OFF; remove the jumper wire from the terminal. reapply the jumper wire, turn the ignition On and check for leaks.
    10.  

  6.  

Mazdaspeed6
  1. Disconnect the negative battery cable.
  2.  
  3. Before servicing the vehicle, refer to the precautions section.
  4.  
  5. Remove the charge air cooler cover.
  6.  
  7. Remove the battery and tray.
  8.  
  9. Remove the air cleaner.
  10.  
  11. Remove the resonance chamber, remove the left hand front mudguard before removing the resonance chamber.
  12.  
  13. Disconnect the MAF/IAT sensor.
  14.  
  15. Remove the duct.
  16.  
  17. Remove the charge air cooler cover.
  18.  
  19. Remove the charge air cooler.
  20.  
  21. Remove the charge air cooler bracket.
  22.  
  23. Remove the air bypass valve.
  24.  
  25. Drain and recycle the engine coolant.
  26.  
  27. Remove the throttle body.
  28.  
  29. Disconnect the EGR valve connector.
  30.  
  31. Remove the air hose.
  32.  
  33. Remove the high pressure fuel pump bracket and the EGR pipe bracket.
  34.  
  35. Remove the fuel delivery pipe cover.
  36.  
  37. Remove the oil level gauge pipe.
  38.  
  39. Remove the drive belt.
  40.  
  41. Remove the power steering pump out of the way with the lines still attached.
  42.  
  43. Remove the vacuum hose.
  44.  
  45. Remove the intake manifold.
  46.  

To install:

  1. Installation is the reverse of removal, note the following:
    1. Tighten the intake manifold bolts to 13-16 ft. lbs. (17-23 Nm).
    2.  
    3. Tighten the fuel delivery pipe cover bolts to 13-16 ft. lbs. (17-23 Nm).
    4.  
    5. Tighten the charge air cooler bracket to 31-35 ft. lbs. (42-48 Nm).
    6.  
    7. Tighten the charge air cooler to 14-19 ft. lbs. (42-48 Nm).
      CAUTION
      When installing the charge air cooler cover, be careful not to damage the charge air cooler cover clips.

    8.  
    9. Tighten the throttle body installation bolts to 71-101 inch lbs. (8-11.5 Nm).
    10.  
    11. Perform the following when installing the air cleaner case:

      Verify that the rubber mounts are set in the air cleaner bracket
       
      Install the projections on the frame side.
       
      Verify that the projections on the frame side are installed securely.
       
      Install the projection on the engine side.
       
      Verify that the projection on the engine side installed securely.
       

    12.  

  2.  

 
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