Intake Manifold Removal/Installation - 4.0L

Disconnect the negative battery cable. See BATTERY DISCONNECT .

Fig 1: Removing Accelerator Control Splash Shield
Courtesy of MAZDA MOTORS CORP.
Remove the accelerator control splash shield.

Fig 2: Removing Air Cleaner Outlet Pipe
Courtesy of MAZDA MOTORS CORP.
Remove the air cleaner outlet pipe.
- Disconnect the tube.
- Detach the mass airflow (MAF) sensor wiring pin-type retainer.
- Loosen the clamps and remove the pipe.
  
  Fig 3: Disconnecting Idle Air Control Valve, Throttle Position Sensor Electrical Connectors
  Courtesy of MAZDA MOTORS CORP.
Disconnect the idle air control (IAC) valve, throttle position (TP) sensor electrical connectors and the TP sensor wiring pin-type retainer.

Fig 4: Disconnecting MAF Sensor Wiring Pin-Type Retainer
Courtesy of MAZDA MOTORS CORP.
Disconnect the MAF sensor wiring pin-type retainer.

Fig 5: Disconnecting Accelerator And Cruise Control Cables
Courtesy of MAZDA MOTORS CORP.
Disconnect the accelerator and cruise control cables.
1. Detach the accelerator and cruise control cables from the throttle body.
2. Detach the accelerator and cruise control cables from the bracket, and position the cables aside.
  
  Fig 6: Disconnecting Exhaust Gas Recirculation Valve Vacuum Hose - With Torque Specifications
  Courtesy of MAZDA MOTORS CORP.
Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.

Fig 7: Disconnecting EGR Vacuum Regulator Solenoid Valve Electrical Connector And Vacuum Hose
Courtesy of MAZDA MOTORS CORP.
Disconnect the EGR vacuum regulator solenoid valve electrical connector and vacuum hose.

Fig 8: Disconnecting Vacuum Hose
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Late build vehicles shown, early build vehicles similar.
Disconnect the hose.

Fig 9: Disconnecting Brake Booster Vacuum Hose
Courtesy of MAZDA MOTORS CORP.
Loosen the clamp and disconnect the brake booster vacuum hose.

Fig 10: Removing Spark Plug Wire Routing Clip Pin-Type Retainer
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
NOTE:
- Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wire locations before removing them.
Disconnect the RH spark plug wires from the coil. Remove the spark plug wire routing clip pin-type retainer and position the wires aside.

Fig 11: Removing Accelerator Cable Routing Clip Pin-Type Retainer
Courtesy of MAZDA MOTORS CORP.
Remove the accelerator cable routing clip pin-type retainer and the wiring harness pin-type retainer.

Fig 12: Removing Bolts - With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the bolts.

Fig 13: Removing Coil And Bracket - With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the bolts and position the coil and bracket aside.

Fig 14: Disconnecting Vacuum Hoses
Courtesy of MAZDA MOTORS CORP.
Disconnect the vacuum hoses.

Fig 15: Removing Nut
Courtesy of MAZDA MOTORS CORP.
Remove the nut.

Fig 16: Disconnecting Powertrain Control Module Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Disconnect the powertrain control module (PCM) electrical connector.

Fig 17: Removing Retainer And Ground Wires
Courtesy of MAZDA MOTORS CORP.
Remove the retainer and position the ground wires aside.

Fig 18: Detaching Electrical Connector Retainer
Courtesy of MAZDA MOTORS CORP.
Detach the electrical connector retainer.

Fig 19: Removing Intake Manifold Bolts - With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the intake manifold bolts and lift up the intake manifold.

Fig 20: Removing Heated Positive Crankcase Ventilation Hose Retainers - With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.
Remove the intake manifold.
To install, reverse the removal procedure.