Cooling System Bleeding: Removal & Installation Mazda MPV II

Removal

1. Disconnect negative battery cable.
2. Drain cooling system.
3. Drain transaxle fluid.
4. Disconnect P/S pump pipes, and drain reservoir.
5. Remove the splash shield (RH).
6. Remove the joint shaft (RH).
7. Disconnect the driveshaft (LH) from the transaxle.
8. Remove battery and battery tray.
9. Remove air cleaner, intake air duct, acclerator cable and bracket, and vacuum hose.
10. Remove transmission filler tube and selector cable (A/T).
11. Remove cruise control actuator.
12. Remove radiator.
13. Using Special Tool (49UN01052) for 3/8" hose or (49UN01052) for 1/2" hose, disconnect plastic fuel hose quick release connector. (Scheme 1)
14. Disconnect PCM wiring harness at PCM.
15. Pull harness through dash lower panel into engine compartment.
16. Remove front exhaust pipe.
17. Remove drive belt.
18. Remove A/C compressor with hoses attached, and secure components aside.
19. Remove generator and bracket.
20. Remove No. 2 engine mount nut.
21. Remove engine mount member.
22. Remove No. 1 engine mount through-bolt.
23. Remove No. 1 engine joint bracket
24. Remove No. 3 engine joint bracket.
25. Remove No. 3 engine mount rubber.
26. Remove No. 4 engine mount through-bolt.
27. Remove No. 4 engine joint bracket.
28. Remove No. 4 engine mount rubber.
29. Remove engine and transaxle from vehicle.

Installation

1. Install engine and transaxle. Install No. 4 joint bracket and through bolt joining rubber to joint bracket. Tighten center nut, then tighten side nuts. Install No. 3 engine mount rubber and joint bracket. DO NOT tighten bolt until engine position has been adjusted. Install No. 1 engine joint bracket, No. 1 engine mount through bolt and engine mount crossmember. Install No. 2 engine mount nut.
2. Ensure No. 3 mount rubber center bolt is centered in bracket. Tighten No. 1 and No. 4 engine mount through-bolts. Tighten No. 3 engine mount center nut to 56-76 ft. lbs. (76-103 Nm).
3. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-98839-S35879678022001053000000). Fill engine with oil. Fill automatic transaxle with Dexron II ATF or manual transaxle with SAE 75W-90 gear oil with API rating of GL-4 or GL-5.
4. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-98839-S26824213612001053000000). Ensure accelerator cable has.06-.15" (1.5-3.8 mm) free play at throttle body when installed. (Scheme 3) If free play is not as specified, move white locking tab to unlock position.
5. Turn stopper to unlock position. If stopper will not unlock, carefully bend tab out using a suitable tool. Push or pull throttle cable directly behind spring. (Scheme 4) Turn stopper to lock position. Ensure cable free play is within specification. Move locking tab to lock position. Ensure correct accelerator operation.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-98839-S12079595932001053000000). Drain cooling system. Disconnect negative battery cable.
2. Remove air cleaner assembly. Remove fuse box, battery and battery tray to remove fresh-air duct. Remove front, left-side mudguard and resonance chamber. Remove MAF sensor and air hose. Disconnect necessary control cables, electrical connections, coolant hoses, vacuum hoses and fuel lines.
3. Remove throttle body, EGR valve, IAC valve and PRC solenoid valve. Loosen intake manifold retaining bolts and nuts evenly using several steps. Remove intake manifold assembly and gaskets. (Scheme 5)
4. If removing fuel injectors, remove retaining bolts, fuel injector retainer, insulators, fuel injectors, fuel rail and pressure regulator, and fuel rail insulators (if necessary). (Scheme 5) Fuel rail insulators are located between fuel rail and intake manifold.

1. To install fuel injectors, install NEW "O" rings on fuel injector. Coat "O" rings with engine oil. Using twisting motion, install fuel injector into fuel rail so notch on side of fuel injector engages notch in fuel rail.
2. Install NEW insulators and "O" rings onto fuel rail. Install and tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98839-S35879678022001053000000). To install remaining components, reverse removal procedure. Install all intake manifold retaining bolts and nuts before tightening to specification. Tighten intake manifold bolts in order. (Scheme 6)Tighten all fasteners evenly to specification. See «TORQUE SPECIFICATIONS»(ref-98839-S35879678022001053000000).
3. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-98839-S26824213612001053000000). Ensure accelerator cable has.06-.16" (1.5-4.1 mm) deflection at throttle body when installed. If deflection is not as specified, rotate nut on end of cable at throttle body until specified deflection is obtained.

Scheme 5

Scheme 6