How do you remove the intake manifold on a Mazda 6 4cylinder 2.3L?

Answer 1

with some patience and small hands you can do it. Removal is always harder then installation as you get familiar with the procedure. If you need help i can do a step by step, i just finished fabricating a new hose for a pcv and reinstalling it. You can not get the molded hose from an auto parts store, i used 2 90 degree elbows and 3 pieces of hose, this makes the hose more durable with less span between connections and less chance of another crack in it.

Remember,

1: unplug negative batter cable.

2: remove throttle body for easier removal of intake manifold, 2 water hoses on throttle body, one sensor plug , 4 bolts. And tube from filter box 2 Phillips screws loosened. vacuum hose on that tube from filter box also. And a sensor to unplug on that tube (maf sensor).

3: disconnect 2 sensors on intake manifold on the top front, disconnect 2 sensors plugs on bottom right side of manifold, there are 2 hoses above the two bottom sensors you need to unplug, tricky part is removing the wire harness from the manifold, very tight space there are two connected to the front of manifold, and 3 on the left side.

4: remove 2 bolts holding dipstick tube to manifold.

5: now everything should be out of the way or movable to get the manifold out. There are 8 bolts holding it on, 4 on the top, one you have to get to under the car, one by the Power Steering pump(left side lower), one through a hole in the middle of the manifold (the hardest one i think) and one below the area where the throttle body was unbolted. I also removed the retainers on the front of the car holding the radiator and fans in place to be able to move them back to get it out, you may need someone to push the radiator back as you maneuver the manifold out, there is a vacuum hose on the backside of the manifold that goes to the pcv valve, it is very hard to get back on also when u reinstall. Tight space to put it back on. I tilted the right side up to get it clear that pipe going into it then lifted at an angle to get the tabs past the fuel rail and it was out, took me about 3 hours to remove, clean it all up and 1 1/2 hours to reinstall, I'm a little slow but i got it done.

When the manifold is out i used 5 old rags and stuffed them into the holes so a catastrophic accident don't happen. Make sure the areas are clean and no sand or dirt may be there.

I believe that is all of it, if you get stuck you can email me and i will try to get back to you fast if possible.