Mazda Trucks 1987-1993 Repair Guide

Throttle Body

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REMOVAL & INSTALLATION



Pickup

See Figures 1 and 2

  1. Disconnect the negative battery ground cable.
  2.  
  3. Disconnect the air hose.
  4.  
  5. Disconnect the ventilation hose.
  6.  
  7. Remove the air pipe and resonance chamber.
  8.  
  9. Disconnect the accelerator cable from the throttle lever.
  10.  
  11. Drain the engine coolant.
  12.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the coolant lines at the manifold.
  2.  
  3. Tag and disconnect all vacuum hoses.
  4.  



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Fig. Fig. 1: Exploded view of the air hose and resonance chamber assembly



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Fig. Fig. 2: Removal of throttle body components

  1. Tag and disconnect all wiring.
  2.  
  3. Unbolt and remove the throttle body.
  4.  
  5. Always use a new mounting gasket. Place the new gasket and throttle body in position. Install and torque the fasteners to 15 ft. lbs. Connect the vacuum lines, hoses and intake system components. Fill the cooling system.
  6.  

MPV With The 2.6L Engine

See Figures 1 and 2

  1. Disconnect the battery ground.
  2.  
  3. Disconnect the air hose.
  4.  
  5. Disconnect the ventilation hose.
  6.  
  7. Remove the air pipe and resonance chamber.
  8.  
  9. Disconnect the accelerator cable from the throttle lever.
  10.  
  11. Drain the engine coolant.
  12.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the coolant lines at the manifold.
  2.  
  3. Tag and disconnect all vacuum hoses.
  4.  
  5. Tag and disconnect all wiring.
  6.  
  7. Unbolt and remove the throttle body.
  8.  
  9. Always use a new mounting gasket. Place the new gasket and throttle body in position. Install and torque the fasteners to 15 ft. lbs. (20 Nm). Connect the vacuum lines, hoses and intake system components. Fill the cooling system.
  10.  

3.0L Engine

See Figures 3 and 4

The throttle body is located at the left end of the air intake plenum. The throttle body contains the throttle position sensor and the automatic idle speed motor.

  1. Disconnect battery negative cable.
  2.  
  3. Loosen air cleaner to throttle body hose clamps and remove hose.
  4.  
  5. Remove accelerator cable and transaxle kickdown linkage.
  6.  
  7. Remove harness connector from throttle position sensor (TPS), and automatic idle speed (AIS) motor.
  8.  



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Fig. Fig. 3: Loosen the air cleaner-to-throttle body hose clamps (A) and remove hose, then disconnect the accelerator cable (B)



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Fig. Fig. 4: Remove the throttle body and replace the mounting gasket

  1. Label and remove vacuum hoses necessary.
  2.  
  3. Remove throttle body mounting nuts and remove throttle body and gasket.
  4.  
  5. Install throttle body using a new gasket on air intake plenum. Secure with mounting nuts. Tighten the mounting nuts to 14-18 ft. lbs. (19-25 Nm).
  6.  
  7. Reconnect vacuum hoses, TPS and ASI electrical connectors.
  8.  
  9. Reconnect accelerator cable and transaxle linkage.
  10.  
  11. Install air cleaner to throttle body hose and tighten clamps.
  12.  
  13. Reconnect battery negative cable.
  14.  

4.0L Engine

See Figures 5 through 11



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Fig. Fig. 5: To remove the throttle body, first remove the air intake hose, then the linkage shield

  1. Disconnect the negative battery cable. Remove the air cleaner intake hose.
  2.  
  3. Remove the linkage shield.
  4.  
  5. Disconnect the throttle cable at the ball stud.
  6.  
  7. Disconnect the canister purge hose from under the throttle body.
  8.  
  9. Disconnect the wiring harness at the throttle position sensor.
  10.  



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Fig. Fig. 6: Next, disconnect the throttle control cable(s) from the throttle body ...



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Fig. Fig. 7: ... as well as any electrical connections...



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Fig. Fig. 8: ... and vacuum fittings. Make sure to label them to assure proper installation



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Fig. Fig. 9: Remove the throttle body-to-upper intake attaching bolts ...



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Fig. Fig. 10: ... then remove the throttle body assembly



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Fig. Fig. 11: Remove the old gasket and thoroughly clean the mating surfaces of both pieces

  1. Remove the 4 retaining bolts and lift the throttle body assembly off the upper intake manifold.
  2.  
  3. Remove and discard the gasket.
  4.  

To install:
  1. Clean and inspect the mounting faces of the throttle body assembly and the upper intake manifold. Both surfaces must be clean and flat.
  2.  
  3. Install a new gasket on the manifold.
  4.  
  5. Install the air throttle body assembly on the intake manifold.
  6.  
  7. Install the bolts finger tight, then tighten them evenly to 76-106 inch lbs. (8-12 Nm).
  8.  
  9. Connect the wiring harness to the throttle position sensor.
  10.  
  11. Install the canister purge hose.
  12.  
  13. Install the snow shield and air cleaner outlet tube. Reconnect the battery cable. Start engine, check for proper operation.
  14.  

 
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