Mazda MPV 1999-06

Intake Manifold

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Removal & Installation



2.5L 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
     
    Air cleaner housing and fresh air duct
     
    Mass Air Flow (MAF) sensor
     
    Throttle body intake hose
     
    Accelerator cable and bracket
     
    Intake Manifold Runner Control (IMRC) cable at the IMRC housing
     
    Throttle body
     
    Exhaust Gas Recirculation (EGR) valve
     
    Idle Air Control (IAC) valve
     
    Pressure Regulator Control (PRC) solenoid
     
    Intake manifold
     
    Fuel lines
     
    Fuel pressure regulator vacuum line
     
    Fuel supply manifold
     
    IMRC housing
     

  6.  

To install:

  1. Install or connect the following:

    IMRC housing. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    Fuel supply manifold. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    Fuel pressure regulator vacuum line
     
    Fuel lines
     
    Intake manifold. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    PRC solenoid. Tighten the bolt to 45-61 inch lbs. (5-7 Nm).
     
    IAC valve. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    EGR valve
     
    Throttle body. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    IMRC cable
     
    Accelerator cable and bracket. Tighten the bolt to 71-94 inch lbs. (8-11 Nm).
     
    Throttle body intake hose
     
    MAF sensor
     
    Air cleaner housing and fresh air duct
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner housing and fresh air duct
     
    Mass Air Flow (MAF) sensor
     
    Throttle body intake hose
     
    Accelerator cable and bracket
     
    Intake Manifold Runner Control (IMRC) cable at the IMRC housing
     
    Throttle body
     
    Exhaust Gas Recirculation (EGR) valve
     
    Idle Air Control (IAC) valve
     
    Pressure Regulator Control (PRC) solenoid
     
    Intake manifold
     
    Fuel lines
     
    Fuel pressure regulator vacuum line
     
    Fuel supply manifold
     
    IMRC housing
     

  6.  

To install:

  1. Install or connect the following:

    IMRC housing. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    Fuel supply manifold. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    Fuel pressure regulator vacuum line
     
    Fuel lines
     
    Intake manifold. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    PRC solenoid. Tighten the bolt to 45-61 inch lbs. (5-7 Nm).
     
    IAC valve. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    EGR valve
     
    Throttle body. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    IMRC cable
     
    Accelerator cable and bracket. Tighten the bolt to 71-94 inch lbs. (8-11 Nm).
     
    Throttle body intake hose
     
    MAF sensor
     
    Air cleaner housing and fresh air duct
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  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
     
    Air cleaner housing and fresh air duct
     
    Mass Air Flow (MAF) sensor
     
    Throttle body intake hose
     
    Accelerator cable and bracket
     
    Intake Manifold Runner Control (IMRC) cable at the IMRC housing
     
    Throttle body
     
    Exhaust Gas Recirculation (EGR) valve
     
    Idle Air Control (IAC) valve
     
    Pressure Regulator Control (PRC) solenoid
     
    Intake manifold
     
    Fuel lines
     
    Fuel pressure regulator vacuum line
     
    Fuel supply manifold
     
    IMRC housing
     

  6.  

To install:

  1. Install or connect the following:

    IMRC housing. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    Fuel supply manifold. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    Fuel pressure regulator vacuum line
     
    Fuel lines
     
    Intake manifold. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    PRC solenoid. Tighten the bolt to 45-61 inch lbs. (5-7 Nm).
     
    IAC valve. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    EGR valve
     
    Throttle body. Tighten the bolts to 72-105 inch lbs. (8-12 Nm).
     
    IMRC cable
     
    Accelerator cable and bracket. Tighten the bolt to 71-94 inch lbs. (8-11 Nm).
     
    Throttle body intake hose
     
    MAF sensor
     
    Air cleaner housing and fresh air duct
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.0L 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
     
    Air cleaner housing and fresh air duct
     
    Resonance chamber
     
    Mass Air Flow (MAF) sensor
     
    Throttle body intake hose
     
    Accelerator cable and bracket
     
    IMCC actuator
     
    Throttle body
     
    Exhaust Gas Recirculation (EGR) valve
     
    Idle Air Control (IAC) valve
     
    Dynamic chamber
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    Dynamic chamber. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     

  2.  
  3. The remainder if installation is the reverse of removal.
  4.  
  5. Start the engine and check for leaks.
  6.  


    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-3.0L engine



    Click image to see an enlarged view

    Fig. Dynamic chamber torque sequence-3.0L engine




Click image to see an enlarged view

Fig. Exploded view of the intake air system-3.0L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct
     
    Air intake hose
     
    Air cleaner assembly
     
    Mass Air Flow (MAF) sensor
     
    Accelerator cable
     
    Cruise control cable
     
    Idle Air Control (IAC) valve connector and hoses
     
    Bypass air solenoid valve connector, if equipped
     
    Vacuum solenoid valve connectors
     
    Upper radiator hose
     
    Heater hose
     
    Bypass hose
     
    Intake manifold vacuum lines
     
    Upper intake manifold
     
    Fuel lines
     
    Fuel supply manifold
     
    Lower intake manifold
     

  8.  

To install:

  1. Install the lower intake manifold with new gaskets. Install the washers with the white paint marks facing UP . Tighten the nuts to 14-18 ft. lbs. (19-25 Nm).
  2.  
  3. Install or connect the following:

    Fuel supply manifold. Tighten the nuts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines
     
    Upper intake manifold. Tighten the bolts to 70-95 inch lbs. (8-11 Nm).
     
    Intake manifold vacuum lines
     
    Bypass hose
     
    Heater hose
     
    Upper radiator hose
     
    Vacuum solenoid valve connectors
     
    Bypass air solenoid valve connector, if equipped
     
    IAC valve connector and hoses
     
    Accelerator cable
     
    Cruise control cable
     
    MAF sensor
     
    Air cleaner assembly
     
    Air intake hose
     
    Fresh air duct
     
    Negative battery cable
     

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

  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
     
    Air cleaner housing and fresh air duct
     
    Resonance chamber
     
    Mass Air Flow (MAF) sensor
     
    Throttle body intake hose
     
    Accelerator cable and bracket
     
    IMCC actuator
     
    Throttle body
     
    Exhaust Gas Recirculation (EGR) valve
     
    Idle Air Control (IAC) valve
     
    Dynamic chamber
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).
     
    Dynamic chamber. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-3.0L engine



    Click image to see an enlarged view

    Fig. Dynamic chamber torque sequence-3.0L engine

     

  2.  
  3. The remainder if installation is the reverse of removal.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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