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Intake Manifold Removal/Installation - 2.3L: Installation

WARNING: This page is about a different car, the 2005 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Installing New Intake Manifold Gaskets
G03728928Courtesy of MAZDA MOTORS CORP.
  1. Inspect and install new intake manifold gaskets, if necessary.
    Fig 2: Installing Intake Manifold And Mounting Bolts
    G03728929Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Engine removed for clarity.
  2. Install the intake manifold and the five mounting bolts.
  3. Connect the wiring push pin to the bottom of the intake manifold.
  4. Connect fuel supply tube to the manifold. See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL/INSTALLATION .
    Fig 3: Connecting Engine KS Connector To Intake Manifold
    G03728930Courtesy of MAZDA MOTORS CORP.
  5. Connect the engine KS connector to the intake manifold and connect the electrical connector.
    Fig 4: Installing 42-Pin Electrical Connector To Bracket
    G03728931Courtesy of MAZDA MOTORS CORP.
  6. Attach the 42-pin electrical connector to the bracket and connect the vapor purge hose.
    Fig 5: Installing EGR Flange Mounting Bolts - With Torque Specifications
    G03728932Courtesy of MAZDA MOTORS CORP.
  7. Install the EGR flange mounting bolts.
    Fig 6: Connecting Fuel Hose Into Clip
    G03728933Courtesy of MAZDA MOTORS CORP.
  8. Connect the fuel hose into the clip.
    Fig 7: Installing EGR Tube Bracket Bolt
    G03728934Courtesy of MAZDA MOTORS CORP.
  9. Install the EGR tube bracket bolt.
    Fig 8: Installing Bracket - With Torque Specifications
    G03728935Courtesy of MAZDA MOTORS CORP.
  10. Install the bracket.
    Fig 9: Connecting Pin-Type Retainers
    G03728936Courtesy of MAZDA MOTORS CORP.
  11. Position the engine wiring harness and connect the pin-type retainers.
    Fig 10: Connecting Engine Vacuum Harness, Brake Booster Hose And Crankcase Breather Hose
    G03728937Courtesy of MAZDA MOTORS CORP.
  12. Connect the engine vacuum harness, brake booster hose and the crankcase breather hose. Connect the coolant hoses.
    Fig 11: Connecting Vapor Purge Hose And IAC Valve Electrical Connector
    G03728938Courtesy of MAZDA MOTORS CORP.
  13. Connect the vapor purge hose and the IAC valve electrical connector.
    Fig 12: Connecting MAP Sensor Electrical Connector
    G03728939Courtesy of MAZDA MOTORS CORP.
  14. Connect the MAP sensor electrical connector.
    Fig 13: Connecting TP Sensor Electrical Connector
    G03728940Courtesy of MAZDA MOTORS CORP.
  15. Connect the TP sensor electrical connector.
    Fig 14: Connecting Throttle Cables To Intake Manifold And Throttle Body
    G03728941Courtesy of MAZDA MOTORS CORP.
  16. Connect the throttle cables to the intake manifold and the throttle body.
    1. Connect the accelerator cable and cruise control cable (if so equipped) into the mounting bracket.
    2. Connect the accelerator cable and cruise control cable (if so equipped) onto the throttle linkage.
  17. Install the air cleaner outlet pipe. See AIR CLEANER OUTLET PIPE REMOVAL/INSTALLATION - 2.3L  .
  18. Install the accelerator control splash shield.
  19. Fill and bleed the engine cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L .
    Fig 15: Installing Accelerator Control Splash Shield
    G03728942Courtesy of MAZDA MOTORS CORP.
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