Intake Manifold Removal / Installation - 4.0L

Fig 1: Removing/Installing Intake Manifold 4.0L (1 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 2: Removing/Installing Intake Manifold With Torque Specifications 4.0L (2 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 3: Removing/Installing Intake Manifold With Torque Specifications 4.0L (3 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 4: Removing/Installing Intake Manifold With Torque Specifications 4.0L (4 Of 5)

Courtesy of MAZDA MOTORS CORP.

Fig 5: Removing/Installing Intake Manifold With Torque Specifications 4.0L (5 Of 5)

Courtesy of MAZDA MOTORS CORP.

1. Disconnect the negative battery cable. See BATTERY DISCONNECT , .
   Fig 6: Removing Accelerator Control Splash Shield

   Courtesy of MAZDA MOTORS CORP.
2. Remove the accelerator control splash shield.
   Fig 7: Removing Air Cleaner Outlet Pipe

   Courtesy of MAZDA MOTORS CORP.
3. 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 8: Disconnecting Idle Air Control (IAC) Valve, Throttle Position (TP) Sensor Electrical Connectors

   Courtesy of MAZDA MOTORS CORP.
4. Disconnect the idle air control (IAC) valve, throttle position (TP) sensor electrical connectors and the TP sensor wiring pin-type retainer.
   Fig 9: Disconnecting MAF Sensor Wiring Pin-Type Retainer

   Courtesy of MAZDA MOTORS CORP.
5. Disconnect the MAF sensor wiring pin-type retainer.
   Fig 10: Disconnecting Accelerator And Cruise Control Cables

   Courtesy of MAZDA MOTORS CORP.
6. 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 11: Removing/Installing Exhaust Gas Recirculation (EGR) Valve Vacuum Hose And Tube Fitting With Torque Specifications

   Courtesy of MAZDA MOTORS CORP.
7. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.
   Fig 12: Disconnecting EGR Vacuum Regulator Solenoid Valve Electrical Connector

   Courtesy of MAZDA MOTORS CORP.
8. Disconnect the EGR vacuum regulator solenoid valve electrical connector and vacuum hose.
   Fig 13: Disconnecting Hose

   Courtesy of MAZDA MOTORS CORP.
   NOTE:

   • Late build vehicles shown, early build vehicles similar.
9. Disconnect the hose.
   Fig 14: Disconnecting Clamp And Brake Booster Vacuum Hose

   Courtesy of MAZDA MOTORS CORP.
10. Loosen the clamp and disconnect the brake booster vacuum hose.
    Fig 15: Disconnecting RH Spark Plug Wires From Coil

    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.
11. 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 16: Removing Accelerator Cable Routing Clip Pin-Type Retainer

    Courtesy of MAZDA MOTORS CORP.
12. Remove the accelerator cable routing clip pin-type retainer and the wiring harness pin-type retainer.
    Fig 17: Removing/Installing Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
13. Remove the bolts.
    Fig 18: Removing/Installing Coil And Bracket With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
14. Remove the bolts and position the coil and bracket aside.
    Fig 19: Disconnecting Vacuum Hoses

    Courtesy of MAZDA MOTORS CORP.
15. Disconnect the vacuum hoses.
    Fig 20: Removing Nut

    Courtesy of MAZDA MOTORS CORP.
16. Remove the nut.
    Fig 21: Disconnecting Powertrain Control Module (PCM) Electrical Connector

    Courtesy of MAZDA MOTORS CORP.
17. Disconnect the powertrain control module (PCM) electrical connector.
    Fig 22: Removing Retainer And Position Ground Wires

    Courtesy of MAZDA MOTORS CORP.
18. Remove the retainer and position the ground wires aside.
    Fig 23: Detaching Electrical Connector Retainer

    Courtesy of MAZDA MOTORS CORP.
19. Detach the electrical connector retainer.
    Fig 24: Removing/Installing Intake Manifold Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
20. Remove the intake manifold bolts and lift up the intake manifold.
    Fig 25: Removing/Installing Heated PCV Fitting With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
21. Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.
22. Remove the intake manifold.
23. To install, reverse the removal procedure.