On-Vehicle Installation

WARNING: This page is about a different car, the 2009 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

When installing the control valve body component, do not put the coupler component in the open space of the separate plate in the control valve body component.
Do not pinch the coupler component between the separate plate and the control valve body component.

Fig 1: Identifying Separate Plate

Courtesy of MAZDA MOTORS CORP.

Connect the manual valve link and install the control valve body component.
Temporarily install the control valve body component with the bolts.
Bolt length (measured from below the head)

A: 31 mm {1.220 in}

B: 17 mm {0.669 in}

C: 21 mm {0.827 in}
NOTE:
- Aligning the bolt holes, temporarily tighten the bolt by hand.
Fig 2: Locating Control Valve Body Component Bolts
Courtesy of MAZDA MOTORS CORP.
Temporarily install the suction cover and a new gasket with the bolts.

Fig 3: Identifying Suction Cover & Gasket With Bolts
Courtesy of MAZDA MOTORS CORP.
Tighten the bolts in the order shown in the figure.
Tightening torque

8-12 N.m {82-122 kgf.cm, 72-105 in.lbf}

Fig 4: Identifying Control Valve Body Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.

Fig 5: Identifying VSS Connector & Input/Turbine Speed Sensor Connector
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- If the control valve body cover is installed with the wiring harnesses overlapped, the wiring harnesses may be pinched between the cover and valve body causing the wiring harnesses to be damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the control valve body cover.
Fig 6: View Of Correct Installation Of Control Valve Body Wiring Harnesses
Courtesy of MAZDA MOTORS CORP.
Apply ATF to a new O-ring and install it on the TFT sensor.
Install the TFT sensor with the lock plate and a bolt to the control valve body component as shown in the figure.
Tightening torque

8-12 N.m {82-122 kgf.cm, 72-105 in.lbf}

Fig 7: Identifying TFT Sensor With Lock Plate & Bolt

Courtesy of MAZDA MOTORS CORP.

Connect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.
Connect the coupler component to the clamps.
NOTE:
- Completely remove sealant and oil with white gasoline or similar.
Fig 8: Identifying Coupler Component Clamps
Courtesy of MAZDA MOTORS CORP.
Clean sealant and oil off the contact surface of the transaxle case with the control valve body cover and the bolt holes.
NOTE:
- Completely remove oil with white gasoline or similar.
Clean oil off the contact surface of the new control valve body cover with the transaxle case.

Fig 9: Locating Control Valve Body Cover Bolts
Courtesy of MAZDA MOTORS CORP.
Apply sealant to the new control valve body cover as shown in the figure.
CAUTION:
- If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.
- Be careful that the coupler component will not become caught between the control valve body cover and transaxle case.
Fig 10: Applying Sealant To Control Valve Body Cover
Courtesy of MAZDA MOTORS CORP.
Install the new control valve body cover with new seal bolts.
Tightening torque

9.8-15.7 N.m {100-160 kgf.cm, 87-138 in.lbf}

Fig 11: Locating Control Valve Body Cover Seal Bolts
Courtesy of MAZDA MOTORS CORP.
Install the oil pipe. (See OIL COOLER REMOVAL/INSTALLATION [AW6A-EL] .)
Connect the oil hose to the transaxle. (See OIL COOLER REMOVAL/INSTALLATION [AW6A-EL] .)
Add ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL] .)
Install the aerodynamic under cover NO. 1 (See AERODYNAMIC UNDER COVER NO. 1 REMOVAL/INSTALLATION .)
Install the air cleaner bracket. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
Connect the negative battery cable.
Perform the "Mechanical System Test". (See MECHANICAL SYSTEM TEST [AW6A-EL] .)