Mazda Car 2005-06

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the battery cover.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the air cleaner cover, this involves first removing the MAF/IAT sensor.
  10.  
  11. Remove the air cleaner element.
    1. Remove the air cleaner case.
    2.  

  12.  
  13. Disconnect the quick connect fitting from the air cleaner hose.
  14.  
  15. Remove the air hose by moving the purge solenoid valve slightly out of the way.
  16.  
  17. Remove the fresh-air duct by first removing the bumper.
  18.  
  19. Drain the cooling system.
  20.  
  21. Remove the throttle body.
  22.  
  23. Disconnect the quick connect fitting from the dynamic chamber.
  24.  
  25. Remove the plug hole plate.
  26.  
  27. Remove the service hole cover.
  28.  
  29. Remove the front suspension tower bar.
  30.  
  31. Remove the wiper arm.
  32.  
  33. Remove the cowl grille.
  34.  
  35. Remove the side cowl grille.
  36.  
  37. Move the cooler pipe No.3 and heater pipe slightly out of the way.
  38.  
  39. Remove the service hole cover.
  40.  
  41. Disconnect the heater hose and move the heater pipe slightly out of the way.
  42.  
  43. Disconnect the heater hose and move the heater pipe slightly out of the way.
  44.  
  45. Remove the harness bracket.
  46.  
  47. Remove the under cover.
  48.  
  49. Disconnect the variable intake air solenoid valve, EGR valve, CMP sensor and PSP switch connectors.
  50.  
  51. Disconnect the ignition coil and fuel injector connectors and move the harness aside.
  52.  
  53. Disconnect the quick release connector from the fuel rail.
  54.  
  55. Remove the fuel rail.
  56.  
  57. Disconnect the water hose from the EGR valve.
  58.  
  59. Disconnect two water hoses from the thermostat.
  60.  
  61. Remove the heater hose and heater pipe from the dynamic chamber.
  62.  
  63. Remove the variable intake air solenoid valve.
  64.  
  65. Remove the dynamic chamber installation bolts.
  66.  
  67. Remove the EGR pipe.
  68.  
  69. Disconnect the connector from the A/C compressor.
  70.  
  71. Disconnect the knock sensor connector.
  72.  
  73. Move the vacuum hose between the purge solenoid valve and the charcoal canister aside.
  74.  
  75. Move the clutch release cylinder aside.
  76.  
  77. Disconnect the evaporative hose with the dynamic chamber raised.
  78.  
  79. Remove the dynamic chamber.
  80.  
  81. Remove the intake manifold.

    Click image to see an enlarged view

    Fig. Exploded view of the dynamic chamber and intake manifold-MX-5 Miata

  82.  

To install:

  1. Install the intake manifold and tighten the bolts to 15-25 Nm (12-18 ft. lbs.).
  2.  
  3. Install the dynamic chamber and tighten the bolts to 16-20 Nm (12-14 ft. lbs.)
  4.  
  5. Installation is the reverse order of removal, make sure to tighten the throttle body bolts in the sequence shown to 8-11 Nm (71-100 in. lbs).
  6.  
  7. Check and adjust all fluid levels, start the vehicle and check for proper operation.

    Click image to see an enlarged view

    Fig. Throttle body torque sequence-MX-5 Miata

  8.  

2.3L (L3) Engine


Click image to see an enlarged view

Fig. Exploded view of the intake manifold assembly and related components-Mazda6 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. Remove the variable intake air solenoid valve and the variable tumble solenoid valve.
  26.  
  27. Remove the fuel rail and injectors as an assembly.
  28.  
  29. Disconnect the evaporative hose and vacuum hose from the intake manifold.
  30.  
  31. Remove the intake manifold bolts, the manifold and gasket.
  32.  
  33. Discard the gasket.
  34.  
  35. Clean the mating surfaces of any gasket material.
  36.  

To install:

  1. Install a new gasket and the manifold. Tighten the manifold bolts to 171-101 inch lbs. (8-11.5 Nm).
  2.  
  3. Install the engine oil dipstick tube.
  4.  
  5. Connect the vacuum hose and evaporative hose to the intake manifold.
  6.  
  7. Install the fuel rail and injectors.
  8.  
  9. Install the variable intake air solenoid valve and the variable tumble solenoid valve.
  10.  
  11. Install the throttle body and tighten the bolts to 71-101 inch lbs. (8-11.5 Nm).
  12.  
  13. Install the water hose.
  14.  
  15. Install the air hose.
  16.  
  17. 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.
  18.  
  19. Install the remaining components in the reverse order of removal.
  20.  
  21. Fill the cooling system.
  22.  
  23. 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.  

  24.  

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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