Intake Manifold Removal / Installation - 2.3L: Removal

WARNING: This page is about a different car, the 2007 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.

Drain the engine cooling system. See ENGINE COOLANT REPLACEMENT -- 2.3L .
Remove the accelerator control splash shield.

Fig 1: Locating Accelerator Control Splash Shield Bolts
Courtesy of MAZDA MOTORS CORP.
Remove the air cleaner outlet pipe. See AIR CLEANER OUTLET PIPE REMOVAL / INSTALLATION - 2.3L , .
Disconnect the throttle cables from the intake manifold.

Fig 2: Identifying Accelerator Cable And Throttle Linkage
Courtesy of MAZDA MOTORS CORP.
1. Disconnect the accelerator cable and cruise control cable (if equipped) from the throttle linkage.
2. Disconnect the accelerator cable and cruise control cable (if equipped) from the mounting bracket.
Disconnect the throttle position (TP) sensor electrical connector.

Fig 3: Locating Throttle Position (TP) Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Disconnect the manifold absolute pressure (MAP) sensor electrical connector.

Fig 4: Locating Manifold Absolute Pressure (MAP) Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.

Fig 5: Locating Vacuum Hose And Idle Air Control Valve Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Disconnect the vapor purge tube quick connect coupling.
Disconnect the engine vacuum harness, brake booster hose and the crankcase breather hose. Disconnect the coolant hoses.

Fig 6: Locating Vacuum Harness, Brake Booster Hose And Crankcase Breather Hose
Courtesy of MAZDA MOTORS CORP.
Disconnect two engine wiring harness pin-type retainers from the intake manifold.

Fig 7: Locating Engine Wiring Harness Pin-Type Retainers
Courtesy of MAZDA MOTORS CORP.
Disconnect the pin-type retainer from the rear of the intake manifold.

Fig 8: Locating Pin-Type Retainer
Courtesy of MAZDA MOTORS CORP.
Remove the exhaust gas recirculation (EGR) tube bracket bolt.

Fig 9: Locating Exhaust Gas Recirculation (EGR) Tube Bracket Bolt
Courtesy of MAZDA MOTORS CORP.
Remove the bolts from the EGR tube flange.

Fig 10: Locating EGR Tube Flange Bolts
Courtesy of MAZDA MOTORS CORP.
Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the vapor purge tube quick connect coupling.

Fig 11: Locating Fuel Supply Tube, Electrical Connectors And Vapor Purge Tube Quick Connect Coupling
Courtesy of MAZDA MOTORS CORP.
Disconnect the knock sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.
Remove the wiring harness pushpin from the bottom of the intake manifold.
Disconnect fuel supply tube from the manifold. See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL / INSTALLATION , .
CAUTION:
- Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Remove the 5 bolts and the intake manifold.

Fig 12: Locating Intake Manifold Bolt
Courtesy of MAZDA MOTORS CORP.
- Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging for the silicone gasket remover and metal surface prep.
Remove and discard the intake manifold gaskets.