Mazda RX-8 2004-06

Intake Manifold

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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 the engine and transmission assembly.
  8.  
  9. Remove or disconnect the following:

    Air hose
     
    Air cleaner cover
     
    Variable Fresh Air Duct (VFAD) solenoid valve on high output engines
     
    Vacuum chamber on high output engines
     
    Air cleaner case
     
    Throttle body
     
    Upper extension manifold
     
    Lower extension manifold on high output engines
     
    Oil filler pipe
     
    Air Injection Reactor (AIR) solenoid valve
     
    Secondary Shutter Valve (SSV) solenoid
     
    Variable Dynamic Effect Intake (VDI) solenoid valve.
     
    Air cleaner insulator
     
    Auxiliary Port Valve (APV) bracket and motor on high output engines
     
    Fresh air intake duct
     
    Fuel distributors
     
    Intake manifold and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the air intake system-RX-8



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-RX-8



    Click image to see an enlarged view

    Fig. Applying oil to the APV valves-RX-8



    Click image to see an enlarged view

    Fig. Intake manifold tightening sequence-RX-8

     

  10.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Apply clean oil to the APV valves as shown
  4.  
  5. Install or connect the following:

    Intake manifold using a new gasket in the sequence shown. Torque the bolts to 14-19 ft. lbs. (19-26 Nm). Retighten bolt no. 1.
     
    Fuel distributors and torque the bolts to 14-19 ft. lbs. (19-26 Nm)
     
    Fresh air intake duct and torque the bolts to 69-96 inch lbs. (8-11 Nm)
     
    Auxiliary Port Valve (APV) bracket and motor on high output engines
     
    Air cleaner insulator and torque the bolts to 69-96 inch lbs. (8-11 Nm)
     
    Variable Dynamic Effect Intake (VDI) solenoid valve.
     
    Secondary Shutter Valve (SSV) solenoid
     
    Air Injection Reactor (AIR) solenoid valve
     
    Oil filler pipe and torque the bolts to 79-112 inch lbs. (9-13 Nm)
     
    Lower extension manifold on high output engines and torque the bolts to 79-112 inch lbs. (9-13 Nm)
     
    Upper extension manifold and torque the bolts to 69-96 inch lbs. (8-11 Nm)
     
    Throttle body and torque the bolts to 69-96 inch lbs. (8-11 Nm)
     
    Air cleaner case
     
    Vacuum chamber on high output engines
     
    Variable Fresh Air Duct (VFAD) solenoid valve on high output engines
     
    Air cleaner cover
     
    Air hose
     
    Engine and transmission assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. On models with dynamic suspension, perform the steering angle sensor initialization procedure.
  10.  
  11. Run the engine and check for leaks.
  12.  

 
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