Mazda Car 2002-04

Throttle Body

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Removal & Installation



  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
     
    Intake Air Temperature (IAT) sensor
     
    Air cleaner assembly, Mass Air Flow (MAF) sensor and resonance chamber
     
    Throttle (automatic transaxle only) and accelerator cables
     
    Idle Air Control (IAC) valve and the Throttle Position Sensor (TPS) electrical connectors
     
    Throttle body

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-1.8L (BP) engine

     

  8.  

To install:

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

    Throttle body using a new gasket. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Electrical connectors for the IAC valve and the TPS
     
    Connect and adjust the throttle and accelerator cables
     
    IAT sensor
     
    Air cleaner assembly, MAF sensor and ducts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Run the engine and check for leaks.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly and related components-2.0L (LF) engines



Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly and related components-Mazda 3 with the 2.3L (L3) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the plug hole plate by lifting off and removing the plug hole plate from the areas shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Plug hole plate locations-Mazda 3 models

  8.  
  9. Remove the battery cover and battery duct.
  10.  
  11. Remove the under cover and disconnect the negative battery cable.
  12.  
  13. Remove the intake air cover, the air hose and the air cleaner element.
  14.  
  15. Remove the resonance chamber and air filter element.
  16.  
  17. Remove the strap and the air cleaner case.
  18.  
  19. Remove the fresh air duct.
  20.  
  21. Remove the throttle body.
  22.  

To install:

  1. Install the throttle body and tighten the bolts to 71-101 inch lbs. (8-12 Nm).
  2.  
  3. Install the fresh air duct.
  4.  
  5. Verify the rubber mounts on the battery support bracket are still in place. Insert the air cleaner case into the rubber mounts, using soapy water if necessary to ease installation.
  6.  
  7. Use the strap to secure the shroud panel and the air cleaner case as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Use the strap to secure the shroud panel and the air cleaner case-Mazda 3 models

  8.  
  9. Install the air cleaner element and the resonance chamber.
  10.  
  11. Install the air cleaner cover.
  12.  
  13. Install the air hose, make sure to align the alignment marks on the throttle body and the air hose.

    Click image to see an enlarged view

    Fig. Make sure to align the alignment marks on the throttle body and the air hose-Mazda 3 models

  14.  
  15. Install the intake air cover.
  16.  
  17. Install the under cover.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Install the battery duct and cover.
  22.  
  23. Install the plug hole plate.
  24.  
  25. Fill the cooling system.
  26.  
  27. Start the vehicle and check for leaks as follows:
    1. Using a jumper wire, ground the Powertrain Control Module (PCM) terminals. If equipped with an immobilizer, ground terminal 1AR, if not equipped with an immobilizer, ground terminal 1AQ. Refer to the illustration for terminal location.

      Click image to see an enlarged view

      Fig. If equipped with an immobilizer, ground PCM terminal 1AR, if not equipped with an immobilizer, ground PCM terminal 1AQ-Mazda 3 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.  

  28.  

1.6L (Zm) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel hoses from the fuel rail
     
    Fuel injector electrical connectors
     
    Fuel rail with the injectors connected
     
    Components in the order illustrated

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold, illustrating the removal and installation components with tightening values-1.6L engine

     

  6.  

To install:

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

    Components in the reverse order of the removal sequence
     
    Fuel rail. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines and electrical connectors to the fuel rail
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Run the engine and check for leaks.
  8.  

2.0L (Fs) 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

    Click image to see an enlarged view

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

     

  8.  

To install:

  1. Install or connect the following:

    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.  

  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 resonance assembly
     
    Intake Air Temperature (IAT) sensor
     
    Air cleaner and filter
     
    Mass Air Flow (MAF) sensor
     
    Air hose
     
    Accelerator cable
     
    Throttle body assembly

    Click image to see an enlarged view

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

     

  8.  

To install:

  1. Install or connect the following:

    Throttle body assembly. Torque the bolts and 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.
    12.  

  4.  
  5. Install or connect the following:

    Air hose
     
    AF sensor
     
    Air filter and cleaner
     
    IAT sensor
     
    Fresh air duct and resonance assembly
     
    Negative battery cable
     

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

2.3L (L3) Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly and related components-Mazda 6 with the 2.3L (L3) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the intake air cover and element.
  10.  
  11. Remove the air cleaner case.
  12.  
  13. Remove the VAD check valve.
  14.  
  15. Remove the left front mud guard and resonance chamber.
  16.  
  17. Remove the Mass Airflow (MAF) and Intake Air Temperature (IAT) sensors.
  18.  
  19. Remove the air hose.
  20.  
  21. Remove the water hose.
  22.  
  23. Remove the throttle body.
  24.  
  25. Clean the mating surfaces of any gasket material.
  26.  

To install:

  1. Install the throttle body and tighten the bolts to 71-101 inch lbs. (8-12 Nm).
  2.  
  3. Install the water hose.
  4.  
  5. Install the air hose.
  6.  
  7. Verify the rubber mounts on the air cleaner bracket are still in place. Insert the air cleaner case into the rubber mounts, using soapy water if necessary to ease installation.
  8.  
  9. Install the remaining components in the reverse order of removal.
  10.  
  11. Fill the cooling system.
  12.  
  13. 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-Mazda 6 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.  

  14.  

2.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Dynamic chamber cover
     
    Charge air cooler air duct
     
    Vacuum hoses and electrical connectors from the air cleaner housing
     
    Air cleaner assembly
     
    Fresh air ducts

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly (1 of 2)-2.3L engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly (2 of 2)-2.3L engine



    Click image to see an enlarged view

    Fig. Exploded view of the throttle body assembly (2 of 2)-2.3L (KL) engine

     



    Mass Air Flow (MAF) sensor and the air intake hose from the throttle body
     
    Resonator
     
    Right-hand charge air cooler
     
    Left-hand charge air cooler
     
    Label and disconnect the fuel hoses and electrical connectors from the throttle body. Remove the throttle body
     

  6.  

To install:

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

    Throttle body. Tighten the nuts/bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Remaining components in the reverse of removal.
     

  4.  

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

    Click image to see an enlarged view

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

     

  8.  

To install:

  1. Install or connect the following:

    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

    Click image to see an enlarged view

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

     

  8.  

To install:

  1. Install or connect the following:

    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.  

3.0L (Aj) Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly and related components-Mazda 6 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. Clean the mating surfaces of any gasket material.
  14.  

To install:

  1. Installation is the reverse of removal, please note the following:
  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-Mazda 6 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.  

 
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