Removal and Installation

WARNING: This page is about a different car, the 2007 Mazda B3000. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery. See BATTERY DISCONNECT .
Remove the air cleaner outlet pipe. See AIR CLEANER OUTLET TUBE REMOVAL / INSTALLATION - 3.0L , .
Remove the bolt and the splash shield.

Fig 1: Splash Shield Bolt With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Disconnect the accelerator cable, cruise control cable and return spring.

Fig 2: Locating Accelerator Cable, Speed Control Cable And Return Spring
Courtesy of MAZDA MOTORS CORP.
Disconnect the accelerator cable and cruise control cable from the accelerator bracket.

Fig 3: Locating Accelerator Cable And Speed Control Cable
Courtesy of MAZDA MOTORS CORP.
Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors. Disconnect the wire retainers.

Fig 4: Locating Throttle Position (TP) Sensor And Idle Air Control (IAC) Valve Electrical Connectors
Courtesy of MAZDA MOTORS CORP.
Disconnect the engine vacuum harness-to-vacuum reservoir hose connection.

Fig 5: Locating Engine Vacuum Harness-To-Vacuum Reservoir Hose Connection
Courtesy of MAZDA MOTORS CORP.
Disconnect the exhaust manifold-to-EGR valve tube from the EGR valve.
Tightening torque:

50 Nm {5.1 kgf-m, 37 ft-lbf}
Disconnect the fuel vapor hose from the intake manifold.
Disconnect the EGR vacuum regulator solenoid electrical connector.
Disconnect the brake booster vacuum hose and the positive crankcase ventilation (PCV) valve tube.

Fig 6: Locating Brake Booster Vacuum Hose And Positive Crankcase Ventilation (PCV) Valve Tube
Courtesy of MAZDA MOTORS CORP.
Remove the oil level indicator tube bracket nut and position the tube and bracket out of the way.

Fig 7: Locating Oil Level Indicator Tube Bracket Nut
Courtesy of MAZDA MOTORS CORP.

Tightening torque:

18 Nm {1.8 kgf-m, 13 ft-lbf}
Remove the nut and the upper intake manifold brace.
Tightening torque:

6 Nm (0.6 kgf-m, 53 in-lbf}
Remove the bolts and the upper intake manifold.
- Remove the discard the gaskets.
- Clean and inspect all mating surfaces.
Fig 8: Upper Intake Manifold Bolts With Torque Specification
Courtesy of MAZDA MOTORS CORP.
To install, reverse the removal procedure.

Fig 9: Upper Intake Manifold Bolts Installing Order With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

Install new gaskets and tighten the upper intake manifold bolts in the sequence shown.