Protege 1999-2000

Throttle Body

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Removal & Installation



1.6L (Zm) Engine

Specific to:

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel hoses from the fuel rail
     
    Fuel injector electrical connectors
     
    Fuel rail with the injectors connected
     
    Components in the order illustrated

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold, illustrating the removal and installation components with tightening values-1.6L engine

     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Components in the reverse order of the removal sequence
     
    Fuel rail. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Fuel lines and electrical connectors to the fuel rail
     
    Negative battery cable
     

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

2.0L (Fs) Engine

Specific to:

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

  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 or disconnect the following:

    Negative battery cable
     
    Fresh air duct and resonance assembly
     
    Intake Air Temperature (IAT) sensor
     
    Air cleaner and filter
     
    Mass Air Flow (MAF) sensor
     
    Air hose
     
    Accelerator cable
     
    Throttle body assembly

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly-Protégé with 2.0L (FS) engine

     

  8.  

To install:

  1. Install or connect the following:

    Throttle body assembly. Torque the bolts and nuts to 18 ft. lbs. (25 Nm).
     

  2.  
  3. When connecting the accelerator cable, perform the following adjustment:
    1. Move the white locking tab to the unlock position.
    2.  
    3. Turn stopper B to the to the unlock position.
      NOTE
      If stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

    4.  
    5. Push or pull the cable housing directly behind the spring.
    6.  
    7. Turn the stopper B to the lock position.
    8.  
    9. Measure the free play which should be 0.06-0.15 inch (1.5-4mm) and make sure the cable free play is within specification.
    10.  
    11. Move the white locking tab to the lock position and check for proper accelerator operation.
    12.  

  4.  
  5. Install or connect the following:

    Air hose
     
    AF sensor
     
    Air filter and cleaner
     
    IAT sensor
     
    Fresh air duct and resonance assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

 
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