Intake Manifold Removal / Installation - 4.0L

Fig 1: Identifying Accelerator, Cruise Control Cable With Idle Air Control Motor And Throttle Position Sensor Connector

Courtesy of MAZDA MOTORS CORP.

Fig 2: EGR Replacement Components With Torque Specifications

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Fig 3: Spark Plug And Ignition Coil Replacement Components With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

Fig 4: Wiring Harness Replacement Components With Torque Specifications

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Fig 5: Intake Manifold Replacement Components With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

Disconnect the negative battery cable. See BATTERY DISCONNECT .

Fig 6: Locating Accelerator Control Splash Shield Bolts
Courtesy of MAZDA MOTORS CORP.
Remove the accelerator control splash shield.
Remove the air cleaner outlet tube. See AIR CLEANER OUTLET TUBE REMOVAL / INSTALLATION -4.0L , .
Disconnect the accelerator and cruise control cables.

Fig 7: Identifying Accelerator And Cruise Control Cables With Bracket
Courtesy of MAZDA MOTORS CORP.
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.
Disconnect the idle air control (IAC) valve, throttle position (TP) sensor electrical connectors and the TP sensor wiring pin-type retainer.

Fig 8: Locating Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of MAZDA MOTORS CORP.
Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.

Fig 9: Locating Exhaust Gas Recirculation (EGR) Valve Vacuum Hose And Tube Fitting With Torque Specifications
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Disconnect the EGR vacuum regulator solenoid valve electrical connector and vacuum hose.

Fig 10: Locating EGR Vacuum Regulator Solenoid Valve Electrical Connector
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Loosen the clamp and disconnect the brake booster vacuum hose.

Fig 11: Locating Brake Booster Vacuum Hose
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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 12: Locating RH Spark Plug Wires
Courtesy of MAZDA MOTORS CORP.
Disconnect the ignition coil electrical connector.
Remove the accelerator cable routing clip pin-type retainer and the wiring harness pin-type retainer.
Disconnect the radio interference capacitor electrical connector.
Remove the bolts.

Fig 13: Bracket Bolts With Torque Specifications
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Remove the bolts and position the coil and bracket aside.

Fig 14: Coil And Bracket Side Bolts With Torque Specifications
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Disconnect the vacuum hoses.

Fig 15: Locating Vacuum Hoses
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Remove the wiring harness-to-cowl bracket nut.
Disconnect the 3 PCM electrical connectors.
Remove the wiring harness ground wire stud bolt and position the wiring harness aside.
Tightening torque:

10 Nm {1.0 kgf-m, 89 in-lbf}
Detach the KS electrical connector retainer.

Fig 16: Locating KS Electrical Connector Retainer
Courtesy of MAZDA MOTORS CORP.
Remove the intake manifold bolts and lift up the intake manifold.

Fig 17: Intake Manifold Bolts With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.

Fig 18: Locating Heated PCV Fitting With Torque Specifications
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Remove the intake manifold.
To install, reverse the removal procedure.