On-Vehicle Installation

WARNING: This page is about a different car, the 2005 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.

Connect the manual valve link and install the control valve body component.

Fig 1: Connecting Manual Valve Link
Courtesy of MAZDA MOTORS CORP.
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: Identifying Control Valve Body Component Bolt Locations
  Courtesy of MAZDA MOTORS CORP.
Temporarily install the suction cover and a new gasket with the bolts.

Fig 3: Installing Suction Cover And 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 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: Installing Connector Of VSS
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: Identifying Wiring Harness Precaution
  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: Installing TFT Sensor With Lock Plate
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: Connect the coupler component to the 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 of the contact surface of the new control valve body cover with the transaxle case.

Fig 9: Cleaning Sealant And Oil Off Contact Surface
Courtesy of MAZDA MOTORS CORP.
Apply sealant to the new control valve body cover as shown in the figure.
CAUTION:
- Be careful that the coupler component will not become caught between the control valve body cover and transaxle case.
  
  Fig 10: Applying Sealant To New 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}
Apply ATF to a new O-ring and install it on the oil pipe.
Install the oil pipe and oil hose. (See OIL COOLER REMOVAL/INSTALLATION .)
Connect the lower radiator hose.
Add the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
Add ATF to the specified level. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .)
Install the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
Install the under cover.

Fig 11: Installing Control Valve Body Cover With New Seal Bolts
Courtesy of MAZDA MOTORS CORP.
Install the air cleaner component and air cleaner bracket. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION .)
Connect the negative battery cable.
Perform the mechanical system test. (See MECHANICAL SYSTEM TEST .)