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Removal & Installation (Protege & Protege5)

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2003 Mazda Tribute, 2003 Mazda Protege5, 2003 Mazda Protege, 2003 Mazda MX-5 Miata, and 2003 Mazda MPV. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: When the engine and intake-air system are hot, they can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system.
WARNING: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
WARNING: Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes.
  1. Disconnect the battery negative cable.
  2. Remove in the order indicated in the illustration. See Fig 1. Drain the engine coolant from the radiator before removing the throttle body. Remove the fuel injector before removing the intake manifold. See FUEL RAILS & INJECTORS  under FUEL SYSTEM.
  3. To install, reverse removal procedure. See TORQUE SPECIFICATIONS . To install the dynamic chamber gasket, make sure that the convex side of the gasket is facing the intake manifold side. See Fig 2. To install the intake manifold gasket, make sure that the convex side of the gasket is facing the intake manifold side. See Fig 3.
Fig 1: Removing & Installing Intake Air System - Protege & Protege5
G00256274Courtesy of MAZDA MOTORS CORP.
Fig 2: Installing Dynamic Chamber Gasket - Protege & Protege5
G00256278Courtesy of MAZDA MOTORS CORP.
Fig 3: Installing Intake Manifold Gasket - Protege & Protege5
G00256279Courtesy of MAZDA MOTORS CORP.