Mazda Car 2005-06

Multi-Port Fuel Injection System (MFI)

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Fuel Pressure Regulator



Removal & Installation

The fuel pressure regulator is an integral part of the fuel pump assembly. If the regulator is found to be defective, replace the fuel pump assembly as the pump cannot be disassembled. If the fuel pressure exceeds 50.8-59.4 psi (350-410 kPa) the regulator is defective. If the pressure is below this specification, the pump is defective.

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  

The fuel pressure regulator is an integral part of the fuel pump assembly. If the regulator is found to be defective, replace the fuel pump assembly as the pump cannot be disassembled. If the fuel pressure exceeds 50.8-59.4 psi (350-410 kPa) the regulator is defective. If the pressure is below this specification, the pump is defective.

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  

The fuel pressure regulator is an integral part of the fuel pump assembly. If the regulator is found to be defective, replace the fuel pump assembly as the pump cannot be disassembled. If the fuel pressure exceeds 63-73 psi (430-510 kPa) the regulator is defective. If the pressure is below this specification, the pump is defective.

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Before servicing the vehicle, refer to the precautions section.
  4.  

The fuel pressure regulator is an integral part of the fuel pump assembly. If the regulator is found to be defective, replace the fuel pump assembly as the pump cannot be disassembled. If the fuel pressure exceeds 50.8-59.4 psi (350-410 kPa) the regulator is defective. If the pressure is below this specification, the pump is defective.

Fuel Pump



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. Perform the following procedure to remove the service hole cover.
    1. Remove the console.
    2.  
    3. Remove the quarter trim.
    4.  
    5. Remove the scuff plate.
    6.  
    7. Remove the tire house trim.
    8.  
    9. Remove the aeroboard.
    10.  
    11. Remove the front seat back bar garnish.
    12.  
    13. Remove the remove the back trim.
    14.  
    15. Remove the service hole cover.
    16.  

  10.  
  11. Disconnect the quick release connector from the fuel pump unit.
  12.  
  13. Disconnect the fuel pump unit connector.
  14.  
  15. Remove plate, packing and pump assembly.
  16.  

To install:

  1. Installation is the reverse of removal.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-MX-5 Miata

  2.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the rear seat cushion.
  8.  
  9. Remove the service hole cover.
  10.  
  11. Disconnect the fuel pump electrical connector.
  12.  
  13. Disconnect the hoses from the fuel tank.
    NOTE
    The fuel pump cap can be damaged if there is a gap between the removal/installation tool 49 F042 001. Make sure the tool is attached securely to the cap and that no gap exists between them.

  14.  
  15. Remove the fuel pump ring using tool 49 F042 001.
  16.  
  17. Remove the fuel pump and gaskets from the fuel tank.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Remove the fuel pump ring using tool 49 F042 001-Mazda6 and Mazdaspeed6 models

  18.  

To install:

  1. Install the fuel pump using a new gasket.
    NOTE
    The fuel pump cap can be damaged if there is a gap between the removal/installation tool 49 F042 001. Make sure the tool is attached securely to the cap and that no gap exists between them.

  2.  
  3. Align the fuel pump assembly alignment marks and the floating lines as illustrated.
  4.  
  5. Align the tightening start positions of the cap and the retainer notch as illustrated and tighten them one full turn by hand. If the cap cannot be tightened by hand , remove the cap and make sure the cap is not damaged or misaligned on the retainer or cap and retighten.
  6.  
  7. Make sure the alignment mark and the floating lines are still aligned, tighten the cap to 59-99 ft. lbs. (80-135 Nm) or a rotation angle of 50-140 degrees with the total angle of step 2 and 3 being 410-500 degrees.

    Click image to see an enlarged view

    Fig. Align the fuel pump assembly alignment marks and the floating lines-Mazda6 and Mazdaspeed6 models



    Click image to see an enlarged view

    Fig. Align the tightening start positions of the cap and the retainer notch-Mazda6 and Mazdaspeed6 models

  8.  

Fuel Rail (Supply Manifold) & Injectors



Removal & Installation
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the plug hole plate by lifting off and removing the plug hole plate from the installation areas (rubber and clips) as shown in the illustration.

    Click image to see an enlarged view

    Fig. Remove the plug hole plate-MX-5 Miata

  6.  
  7. Remove the battery cover.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Disconnect the fuel injector connector and move the harness slightly out of the way.
  12.  
  13. Disconnect the quick release connector.
  14.  
  15. Remove the fuel rail bolts and the injectors as an assembly.
  16.  
  17. Remove the injector clip.
    CAUTION
    Use of a deformed injector clip will cause the fuel injector to be connected incorrectly and could result in fuel leakage. It will also cause the injector to rotate. Therefore, always replace the clip when the injector is removed.

  18.  
  19. Insert a flathead screwdriver between the injector cup and clip finger.
    NOTE
    When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch.



    Click image to see an enlarged view

    Fig. Insert a flathead screwdriver between the injector cup and clip finger-MX-5 Miata



    Click image to see an enlarged view

    Fig. When pushing the clip finger outward, deform the finger until it is removed completely from the cup notch-MX-5 Miata

  20.  
  21. Push the clip finger outward using a flathead screwdriver.
  22.  
  23. Remove the injector with the clip.
  24.  
  25. Hold the clip using pliers.
  26.  
  27. Pull the clip parallel to the injector groove and remove it from the injector. Discard the clip.

    Click image to see an enlarged view

    Fig. Pull the clip parallel to the injector groove and remove it from the injector-MX-5 Miata

  28.  

To install:

  1. Apply a small amount of clean oil to the injector groove and the O-ring.
  2.  
  3. Temporarily attach a new clip to the injector groove.
    NOTE
    When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned.

  4.  
  5. Hold the injector firmly and push the clip into the injector until the clip stops sliding.

    Click image to see an enlarged view

    Fig. Hold the injector firmly and push the clip into the injector until the clip stops sliding-MX-5 Miata

  6.  
  7. Verify that the injector connector position is correct.
  8.  
  9. Press the injector into the injector cup. Continue pressing until the clip contacts the lower surface of the injector cup.
  10.  
  11. Verify that the injector and clip are correctly installed with the clip locked onto the injector cup notch.
  12.  
  13. Install the fuel rail and tighten the bolts to 20-26 Nm (15-19 ft. lbs.).
  14.  
  15. Install the remaining components in the reverse order of removal, start the vehicle and check for leaks.
  16.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the plug hole plate.
  6.  
  7. Remove the battery cover and disconnect the negative battery cable.
  8.  
  9. Unplug the injector electrical connections.
  10.  
  11. Disconnect the fuel lines from the rail.
  12.  
  13. Remove the fuel rail bolts.
  14.  
  15. Remove the rail and injectors as an assembly.
  16.  
  17. Insert a flat head screwdriver between the injector cup and clip finger as illustrated.
  18.  
  19. Push the clip finger out using the screwdriver. Deform the finger until it is completely removed from the cup notch.
  20.  
  21. Remove the injector from the clip.
  22.  
  23. Use pliers to pull the clip parallel to the injector groove and remove the clip from the injector. Discard the clip.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-Mazda3 models

  24.  

To install:

  1. Use new O-rings and coat them with clean engine oil.
  2.  
  3. Temporarily attach a new clip to the injector groove.
    NOTE
    When the clip is correctly installed, the central area of the injector and clip finger positions are aligned.

  4.  
  5. While firmly holding the injector, push the clip into the injector until the clip stops. Make sure the injector connector is correctly positioned.
  6.  
  7. Press the injector into the cup until the cup contacts the lower surface of the cup. Make sure the injector and clip are installed properly and the clip is hooked into the injector cup notch.
  8.  
  9. Install the injectors and fuel rail as an assembly.
  10.  
  11. Install the fuel rail bolts and tighten to 15-19 ft. lbs. (20-26 Nm).
  12.  
  13. Attach the fuel lines to the rail.
  14.  
  15. 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 imobilizer, ground terminal 1AQ. Refer to illustration 67162-mazc-g22 for terminal location.
    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.  

  16.  
  17. Install the remaining components.
  18.  


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Unplug the injector electrical connections.
  8.  
  9. Disconnect the fuel lines from the rail.
  10.  
  11. Remove the fuel rail bolts.
  12.  
  13. Remove the rail and injectors as an assembly.
  14.  
  15. Insert a flat head screwdriver between the injector cup and clip finger as illustrated.
  16.  
  17. Push the clip finger out using the screwdriver. Deform the finger until it is completely removed from the cup notch.
  18.  
  19. Remove the injector from the clip.
  20.  
  21. Use pliers to pull the clip parallel to the injector groove and remove the clip from the injector. Discard the clip.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-Mazda6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Insert a flat head screwdriver between the injector cup and clip finger-Mazda3 and 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Deform the finger until it is completely removed from the cup notch-Mazda3 and 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Use pliers to pull the clip parallel to the injector groove and remove the clip from the injector-Mazda3 and 6 models with the 2.3L (L3) engine

  22.  

To install:

  1. Use new O-rings and coat them with clean engine oil.
  2.  
  3. Temporarily attach a new clip to the injector groove.
    NOTE
    When the clip is correctly installed, the central area of the injector and clip finger positions are aligned.

  4.  
  5. While firmly holding the injector, push the clip into the injector until the clip stops. Make sure the injector connector is correctly positioned.
  6.  
  7. Press the injector into the cup until the cup contacts the lower surface of the cup. Make sure the injector and clip are installed properly and the clip is hooked into the injector cup notch.
  8.  
  9. Install the injectors and fuel rail as an assembly.
  10.  
  11. Install the fuel rail bolts and tighten to 15-19 ft. lbs. (20-26 Nm).
  12.  
  13. Attach the fuel lines to the rail.
  14.  
  15. 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.  

  16.  
  17. Install the remaining components.
  18.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the upper intake manifold (dynamic chamber).
  8.  
  9. Disconnect the fuel injector connectors.
  10.  
  11. Disconnect the fuel hoses from the rail.
  12.  
  13. Remove the rail and injectors as an assembly.
  14.  
  15. Gently twist the fuel injector out of the manifold
  16.  
  17. Check the O-rings and replace if damaged.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-Mazda6 models with the 3.0L (AJ) engine

  18.  

To install:

  1. Install the fuel injector(s) using new O-rings lubricated with clean engine oil.
  2.  
  3. Attach the fuel injector into the supply manifold.
  4.  
  5. Install the fuel rail and injectors as an assembly. Tighten the rail bolts to 72-101 inch . lbs. (8-11 Nm).
  6.  
  7. Connect the fuel hoses to the rail.
  8.  
  9. Install the injector connectors.
  10.  
  11. Install the upper intake manifold.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. 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.
    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.  

  16.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Drain and recycle the engine coolant.
    NOTE
    If the high pressure fuel pump is removed, replace the O-ring with a new one.

  10.  
  11. Remove the charge air cooler cover.
  12.  
  13. Disconnect the spill valve control solenoid valve connector.
  14.  
  15. Disconnect the quick release connector on the high pressure fuel pump.
  16.  
  17. Remove the battery and battery tray.
    WARNING
    If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When removing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump joint nut has rotated, replace the high pressure fuel pump with a new one.

  18.  
  19. Disconnect the high pressure line pipe of the high pressure fuel pump.
  20.  
  21. Fix the joint nut with a wrench on the high pressure fuel pump side.
  22.  
  23. Loosen the high pressure line pipe installation nut.
  24.  
  25. Disconnect the fuel delivery pipe.
  26.  
  27. Unplug the injector electrical connections.
  28.  
  29. Remove the fuel injector bract.
  30.  
  31. Remove the injectors as follows:
    1. Install the service tool onto the fuel injector.
      CAUTION
      If the tool slips while ratcheting up the fuel injector, the fuel injector or surrounding parts could be damaged. Press fit the tool to the fuel injector firmly and operate carefully. When ratcheting up the fuel injector, the fuel injector connector may contact the cylinder head and damage the fuel injector. Ratchet up the fuel injector so that the fuel injector connector does not contact the cylinder head.


      NOTE
      If fuel injector No.3 contacts the oil separator, cut the tab on the oil separator. Carefully cut the tab so that the oil separator is not deformed or damaged, with no clearance on the mating surfaces of the oil separator and engine. Keep ratcheting the tool so that the fuel injector becomes free enough to ratchet up without using the tool.


      CAUTION
      Do not apply excessive force to the fuel injector connector because the fuel injector could be damaged. Pull out the fuel injector by ratcheting it upright.

    2.  
    3. Verify that there are no gasket in the cylinder heads after removing the fuel injectors.
      WARNING
      If foreign material such as metal shavings penetrates the fuel injector installation hole on the cylinder block, the engine could be damaged. Remove all foreign material and cap the fuel injector installation hole after removing the fuel injector.

    4.  
    5. Clean the fuel injector and around the insertion hole using a vacuum cleaner.
    6.  

  32.  

To install:

  1. Installation is the reverse of removal, note the following:
    1. Use new O-rings and coat them with clean engine oil.
    2.  
    3. Tighten the fuel pipe delivery bolts to 13-16 ft. lbs. (17-23 Nm).
    4.  
    5. Assemble the high pressure line pipe.
    6.  
    7. Fix the joint nut with a wrench on the high pressure fuel pump side. Tighten the high pressure line pipe installation nut to 17-26 ft. lbs. (23-35 Nm).
    8.  
    9. Tighten the water outlet case installation bolts to 13-16 ft. lbs. (18-22 Nm).
    10.  
    11. Install the quick release connector.
    12.  

  2.  
  3. Verify that the high pressure fuel pump is assembled securely.
  4.  
  5. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.
  6.  
  7. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the high pressure fuel pump.
  8.  

Throttle Body



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.

    Click image to see an enlarged view

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

  22.  

To install:

  1. 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).
  2.  
  3. 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

  4.  

  1. Before servicing the vehicle, refer to the precautions section.

    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-2.3L (L3) engines

  2.  
  3. Before servicing the vehicle, refer to the precautions section.
  4.  
  5. Drain the cooling system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. 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-Mazda3 models

  10.  
  11. Remove the battery cover and battery duct.
  12.  
  13. Remove the under cover and disconnect the negative battery cable.
  14.  
  15. Remove the intake air cover, the air hose and the air cleaner element.
  16.  
  17. Remove the resonance chamber and air filter element.
  18.  
  19. Remove the strap and the air cleaner case.
  20.  
  21. Remove the fresh air duct.
  22.  
  23. Remove the throttle body.
  24.  

To install:

  1. Install the throttle body and tighten the bolts to 71-101 inch lbs. (8-11.5 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-Mazda3 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-Mazda3 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 imobilizer, 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 imobilizer, ground PCM terminal 1AQ-Mazda3 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.  

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.  

To install:

  1. Install the throttle body and tighten the bolts to 71-101 inch lbs. (8-11.5 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-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.  

  14.  

3.0L (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.  

To install:

  1. Install the throttle body and tighten the bolts to 71-101 inch lbs. (8-11.5 Nm).
  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.  

To install:

  1. Installation is the reverse of removal, note the following:
    1. Tighten the throttle body installation bolts to 71-101 inch lbs. (8-11.5 Nm).
    2.  
    3. 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.
       

    4.  

  2.  

 
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