Engine Controls - Removal, Overhaul & Installation: Other Mazda MPV II

THROTTLE BODY

UPPER INTAKE MANIFOLD

Note. Models not listed do not require upper intake manifold to be removed to access fuel system or engine control components.

LYSHOLM COMPRESSOR (MILLENIA 2.3L)

1. Remove dynamic chamber cover. Remove charge air cooler air duct and air cleaner assembly. Remove fresh air duct and connecting air duct. Remove mass airflow sensor and air intake hose.
2. Remove air resonator. Remove right and left air charge air coolers with connecting hoses (if needed) from air intake pipe assembly. Disconnect accelerator cable. Remove EGR valve. Disconnect vacuum lines and harness connector from air intake pipe assembly. Remove air intake pipe assembly.
3. Remove charge air cooler pipe from intake manifold. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-12159-S27442981722000121300000) . Disconnect negative battery cable. Disconnect fuel line. Remove fuel rail assemblies. See «FUEL RAILS & INJECTORS»(ref-12159-S27199478482000121300000) . Disconnect coolant hose. Remove intake manifolds. Remove throttle body from compressor. Loosen and remove drive belt. Remove Lysholm compressor.

Install components in reverse order of removal. Be sure intake manifold bolts are tightened in crisscross pattern to specification. See TORQUE SPECIFICATIONS . Ensure hose clamps are positioned correctly to prevent interference with other hoses or electrical harnesses. Partially tighten air intake pipe bolts. Retighten bolts to specification in a crisscross pattern.

COMPUTERIZED ENGINE CONTROLS

POWERTRAIN CONTROL MODULE

Note. Some models may be equipped with an Immobilizer system. This system can be identified by the ignition key blanks. If the key ring hole on blank has no metal exposed, vehicle is equipped with system. The immobilizer system requires using a CODE WORD for reprogramming keys to PCM. The CODE WORD is only available to the dealer from Mazda.

CAMSHAFT POSITION SENSOR

Note. On Millenia 2.5L, Camshaft Position Sensor (CMP) is integrated with distributor and is not serviced separately. If faulty, distributor assembly must be replaced. See DISTRIBUTOR (MILLENIA 2.5L) .

CAMSHAFT SYNCHRONIZER - 3.0L

1. Position crankshaft to TDC of cylinder No. 1, on compression stroke. Note position of electrical connector on CMP sensor.
2. Disconnect negative battery cable. Unplug harness connector from CMP sensor. Remove CMP sensor screws and CMP sensor from positioner. (Scheme 23) Remove synchronizer hold-down bolt and CMP synchronizer.

1. Install Synchro Positioner (303-589) on synchronizer housing. (Scheme 22) Rotate synchronizer shaft until vane on shaft aligns with slot on synchro positioner. Rotate synchro positioner until engaged into notch in housing. Dip drive gear in engine oil.
2. Install camshaft synchronizer housing assembly. the arrow on the synchro positioning tool should be 38 degrees from centerline of engine. (Scheme 24)
3. Install hold-down clamp and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-12159-S05936474832000121300000). Install CMP sensor to synchronizer and tighten to specification. Reconnect wiring to CMP sensor. Connect negative battery cable.

Scheme 22

Scheme 23

Scheme 24

IGNITION SYSTEM

Note. All models except Millenia 2.5L are equipped with distributorless ignition system.

IGNITION CONTROL MODULE

Note. On Millenia 2.5L, ignition control module is integrated with distributor and is not serviced separately, replace complete distributor assembly.

FUEL SYSTEM

Miata, Millenia, MPV, Protege, Tribute 2.0L & 626

Disconnect fuel pump relay. See FUEL PUMP RELAY LOCATION table. Start engine. Allow engine to run until it stalls. Turn ignition off. Reinstall relay.

FUEL PUMP RELAY LOCATION

Disconnect (Spring Lock Coupler)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-12159-S27442981722000121300000). Remove locking (safety) clip (if equipped). Place Spring Lock Coupler Releaser (49-UN01-051) for 3/8" line, 49-UN01-052 for 1/2" line) over fuel line coupler. (Scheme 25)
2. Push spring lock coupler releaser to release female fitting from garter spring. Pull spring lock coupler apart. Remove releaser.

Connect

1. Check for damaged garter spring. If garter spring is damaged, remove using small hooked wire and replace spring. Wipe end of lines using clean cloth. Place NEW "O" rings onto tube. Lubricate ends of lines with clean refrigerant oil.
2. Push fitting together using a slight twisting motion. Ensure garter spring is over flared end of female fitting. Attempt to pull lines apart to ensure coupler is fully engaged. Install locking clip (if equipped).

Scheme 25

Disconnect (Fuel Line Coupler)

Disengage locking tabs on connector retainer. Separate retainer halves. Disengage fitting from regulator by pushing fitting toward regulator and inserting Fuel Line Coupling Key (49-UN01-006). (Scheme 26)

To reconnect fuel line coupling, push coupler tube assembly firmly into coupler body recess until fully engaged. Pull gently on both ends of coupler to ensure engagement. See FUEL RAILS & INJECTORS .

Scheme 26

Disconnect Fuel Line Coupler

Push apart lock clip and unlock. On blue locking coupler, lift tab and disconnect fuel line. (Scheme 27) On orange locking coupler, rotating coupler until it stops releases fuel line.

Scheme 27

Push fuel lines back together until click is heard. Install locking clip. If installing new fuel line, checker tab will be installed on fuel line coupler. (Scheme 28) Checker tab will release when fuel line coupler is connected completely and can be discarded.

Scheme 28

FUEL LINE CONNECTORS (MIATA, MILLENIA, MPV & 626)

Note. On fuel hose where 2 clamps are used, position clamp tabs more than 45 degrees apart.

Disconnect & Connect (Tabless Design)

Clean quick release connector. Remove fuel line clip. Press tool (49-N013-103) into quick release connector and pull connector apart. Inspect sealing area and clean as necessary. To connect, push connector together until a click is heard. Pull connector to ensure connector is locked together. Reinstall fuel line clip.

Disconnect & Connect (Tab Design)

Clean quick release connector. Squeeze tabs to release connector and pull connector apart. Inspect retainer and replace as necessary. To connect, push connector together until a click is heard. Pull connector to ensure connector is locked together.

FUEL SYSTEM PRIMING

Except B2300, B2500, B3000 & B4000

Connect jumper wire between F/P terminal of data link connector and ground. (Scheme 29) Turn ignition on for about 5 minutes and then off. Disconnect jumper wire.

Scheme 29

FUEL PUMP

FUEL PRESSURE REGULATOR

FUEL RAILS & INJECTORS

CHARCOAL CANISTER

CHARCOAL CANISTER LOCATION

MIATA

TORQUE SPECIFICATIONS (MIATA)

MILLENIA 2.3L

TORQUE SPECIFICATIONS (MILLENIA 2.3L)

MILLENIA 2.5L & 626 2.5L

TORQUE SPECIFICATIONS (MILLENIA 2.5L & 626 2.5L)

MPV

TORQUE SPECIFICATIONS (MPV)

PROTEGE & 626 2.0L

TORQUE SPECIFICATIONS (PROTEGE & 626 2.0L)

TRIBUTE

TORQUE SPECIFICATIONS (TRIBUTE)