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Home >> Mazda >> 2004 >> MX-5 Miata Base, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Engine Mechanical [Intake-Air System]) >> Intake Manifold Removal/Installation >> Notes
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Intake Manifold Removal/Installation: Notes

WARNING: This page is about a different car, the 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" when servicing the fuel system. (See BEFORE REPAIR PROCEDURE .)
  • Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
  • After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction. (See EPS SYSTEM NEUTRAL POSITION SETTING .)
NOTE:
  • The engine must be removed to remove the intake manifold.
  • Remove the engine, transmission, and crossmember component as a single unit downward of the vehicle.
  1. Remove the following parts:
    1. The front wheel and tires.
    2. The engine cover. (See ENGINE COVER REMOVAL/INSTALLATION .)
    3. The front suspension tower bar. (See FRONT SUSPENSION TOWER BAR .)
    4. The battery cover, battery, battery box and battery tray.
    5. The air cleaner, intake-air duct and air cleaner insulator. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION  .)
    6. The PCM.
    7. The AIR pump. (See SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION .)
  2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  3. Disconnect the brake vacuum hose.
  4. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  5. Disconnect the plastic fuel hose. (See BEFORE REPAIR PROCEDURE .)
  6. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION .)
  7. Remove the A/C belt. See SPECIFICATIONS & DRIVE BELT ROUTING .)
  8. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way.
  9. Disconnect the engine wiring harness from the main fuse block side.
  10. Remove the engine under cover.
  11. Disconnect front ABS wheel speed sensor connector. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)
  12. Disconnect the radiator hose, the heater hose and coolant reserve tank hose.
  13. A/T
  14. Remove the engine, transmission, and crossmember component. (See ENGINE REMOVAL/INSTALLATION .)
  15. Remove the extension manifold (upper and lower). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION  .)
  16. Remove the AIR control valve. (See SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION .)
  17. Remove in the order indicated. See Fig 1 .
  18. Install in the reverse order of removal.
    Fig 1: Removing/Installing Intake Manifold
    G01345710Courtesy of MAZDA MOTORS CORP.
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