Engine Controls - Removal, Overhaul & Installation: Other Mazda Tribute I

THROTTLE BODY

UPPER INTAKE MANIFOLD

Note. Upper intake manifold may also be referred to as a dynamic chamber.

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)

Note. Do not remove Air By-Pass Valve (ABV) or Charge Air Cooler (CAC) by-pass actuators unnecessarily.

1. Remove upper intake manifold. See «REMOVAL & INSTALLATION (MILLENIA 2.3L)»(ref-134974-S18513280372002022100000) under UPPER INTAKE MANIFOLD.
2. Disconnect vacuum lines and harness connector from fuel distributor assembly. Remove air intake pipe assembly. Remove Charge Air Cooler (CAC) pipe from intake manifold. Drain coolant from radiator. Remove coolant hoses from By-Pass Air Control (BAC) valve and remove valve. Remove water pipe.
3. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000) . Disconnect negative battery cable. Disconnect fuel line. Remove intake manifolds. Remove throttle body from compressor. Loosen and remove drive belt. Remove Lysholm compressor.

Scheme 34

Note. Before installing Lysholm compressor, temporarily use double sided tape to hold rubber pad to bottom of compressor.

Install components in reverse order of removal. Use NEW gaskets. Be sure intake manifold bolts are tightened in sequence to specification. (Scheme 35) See TORQUE SPECIFICATIONS. Ensure hose clamps are positioned correctly to prevent interference with other hoses or wiring harnesses. Partially tighten air intake pipe bolts. Retighten bolts to specification in a crisscross pattern.

Scheme 35

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 (CMP) sensor is integrated with distributor and is not serviced separately. If faulty, distributor assembly must be replaced. See DISTRIBUTOR (MILLENIA 2.5L) .

Note. Care should be taken when disconnecting Camshaft Position (CMP) sensor harness connector. Wires can be broken easily at connector.

CAMSHAFT SYNCHRONIZER (B3000)

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 37) Remove synchronizer hold-down bolt and CMP synchronizer.

1. Install Synchro Positioner (303-589) on synchronizer housing. (Scheme 36) 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 38)
3. Install hold-down clamp and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000). Install CMP sensor to synchronizer and tighten to specification. Reconnect wiring to CMP sensor. Connect negative battery cable.

Scheme 36

Scheme 37

Scheme 38

CRANKSHAFT POSITION SENSOR

Note. On 4.0L, when installing new Crankshaft Position (CKP) sensor, sensor must be touching damper. CKP sensor has wear tabs that will wear off after several engine revolutions.

Miata

1. Slowly add coolant to radiator until coolant level is up to filler port.
2. Add coolant up to "FULL" mark on coolant reservoir.
3. Tighten cooling system cap on radiator.
4. Start engine and warm up. NOTE: If coolant temperature becomes too high, stop engine to prevent it from overheating.
5. After engine warms up, run it at about 2500 RPM for 5 minutes.
6. Increase engine speed to about 3000 RPM for 5 minutes, then return to idle. Repeat several times.
7. Stop engine and wait until it is cool.
8. Inspect coolant level. If coolant level is low, repeat steps 1 - 6 .
9. Inspect for coolant leakage.

Millenia

Note. On 2.3L, radiator is filled through cooling system reservoir.

Scheme 39

1. Slowly pour coolant into engine up to coolant filler port (2.5L).
2. Fill cooling system reservoir up to "FULL" mark.
3. Tighten engine filler cap (2.5L) and cooling system reservoir cap. (Scheme 39)
4. Start engine and let it idle until it warms up. NOTE: If temperature increases beyond normal, there is excessive air in cooling system. Stop engine and allow it to cool; then repeat Steps 1 - 3.
5. Run engine at 2200-2800 RPM for 5 minutes; repeat several times.
6. Stop the engine and allow it to cool.
7. Remove coolant filler cap (2.5L) and inspect coolant level. If coolant level has dropped, repeat procedure from Step 1.

MPV

Note. Cooling system is filled through coolant reservoir.

1. Add correct coolant mixture to "FULL" mark on coolant reservoir.
2. Tighten cooling system cap on reservoir.
3. Start engine and allow to idle until cooling fan operates.
4. After engine warms up, perform following steps. Run engine at 4000 RPM for one minute. Run engine at idle for one minute. Repeat steps (a) and (b) several times. Turn on main and rear heaters (if equipped) and verify heat from heater vents.
5. Stop engine and wait until it is cool.
6. Inspect coolant level. If coolant level is low, repeat Steps 1 - 5 .
7. Verify there is no coolant leakage.

Protege & Protege5

1. Slowly add coolant to radiator until coolant level is up to filler port.
2. Add coolant up to "FULL" mark on coolant reservoir.
3. Tighten cooling system cap on radiator.
4. Start engine and idle for about 10 minutes. NOTE: If coolant temperature becomes too high, stop engine to prevent it from overheating.
5. After engine warms up, run it at about 2500 RPM for 5 minutes.
6. Increase engine speed to about 3000 RPM for 5 minutes, then return to idle. Repeat several times.
7. Stop engine and wait until it is cool.
8. Inspect coolant level.
9. Inspect for coolant leakage.

Tribute

Note. Radiator is filled through degas bottle.

1. Add engine coolant to degas bottle until coolant level is between "COOLANT FILL LEVEL" marks.
2. Select maximum heater temperature and blower motor speed settings. Position control to discharge air at vents in instrument panel.
3. Start the engine and allow to idle. While engine is idling, feel for hot air at vents. CAUTION: If air discharge remains cool and engine coolant temperature gauge does not move, engine coolant level is low in engine and must be filled. Stop engine, allow to cool and fill cooling system. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from vents. Engine coolant temperature gauge should maintain a stabilized reading in middle of "NORMAL" range and upper radiator hose should feel hot to touch.
4. Shut engine off and allow to cool.
5. Check engine for coolant leaks.
6. Check engine coolant level in degas bottle and fill as necessary.

626

1. Slowly pour coolant into radiator up to coolant filler port (2.0L) or into engine up to coolant filler port (2.5L).
2. Add correct engine coolant mixture to reservoir until coolant level is at "F" mark. Install coolant reservoir cap.
3. Fully install radiator cap (2.0L) or engine filler cap (2.5L) and coolant reservoir cap. (Scheme 39)
4. Start engine and idle for about 10 minutes. NOTE: If coolant temperature becomes too high, stop engine to prevent it from overheating. Repeat steps 1 - 3.
5. After engine warms up, run it at about 2500 RPM for 5 minutes.
6. Increase engine speed to about 3000 RPM for 5 minutes, then return to idle. Repeat several times.
7. Stop engine and wait until it is cool.
8. Inspect coolant level.
9. Inspect for coolant leakage.

IGNITION SYSTEM

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

FUEL SYSTEM

Except B2300, B3000, B4000 & Tribute 3.0L

Remove fuel filler cap to relieve tank pressure. Remove fuel pump relay (disconnect harness connector from fuel pump relay on Miata). See FUEL PUMP RELAY LOCATION table. Start engine. Allow engine to run until it stalls. Turn ignition switch off. Reinstall relay.

FUEL PUMP RELAY LOCATION

Connect

1. Check for damaged garter spring. If garter spring is damaged, remove spring using small hooked wire and replace. 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. Pull gently on both fuel lines to ensure engagement. Install locking clip (if equipped).

Scheme 40

Disconnect - Push Connect Coupling

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Depress retainer clip on coupling. Separate fuel line from coupling. (Scheme 41)

Scheme 41

Wipe end of lines using clean cloth. Align fuel line coupling and push coupling together until a click is heard. Pull gently on both fuel lines to ensure engagement.

Disconnect - Quick Release Coupling

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Depress locking tabs on coupling. Separate fuel line from coupling. (Scheme 42)

Scheme 42

Wipe end of lines using clean cloth. To reconnect fuel line coupling, align fuel line coupling and push coupling together until a click is heard. Pull gently on both fuel lines to ensure engagement.

Disconnect - Quick Release Coupling With "R" Clip

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove shipping tab by bending downward. (Scheme 43) Spread "R" clip legs and push into coupling. (Scheme 44) Separate fuel line from coupling. (Scheme 45)

Scheme 43

Scheme 44

Scheme 45

Wipe end of fuel line using clean cloth. Install NEW "R" clip into coupling. Align fuel line and coupling and push together until click is heard. (Scheme 46) Pull gently on both fuel lines to ensure engagement.

Scheme 46

Disconnect Fuel Line Coupler

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Push apart lock clip and unlock it. If Blue locking tab is used, lift tab on coupling until fuel line can be released. Separate coupler from fuel line. (Scheme 47) If Orange locking coupler is used, rotating coupler 90 degrees until it stops to release internal locking tabs. Blue stopper may be removed from quick connector but must be installed before reconnecting fuel line.

Scheme 47

Inspect fuel hose and fuel line sealing surface for damage or deformation, replace if necessary. Push fuel lines back together until click is heard. Install lock clip. If installing new fuel line, checker tab is integrated on fuel line coupler. (Scheme 48) Checker tab will release when fuel line coupler is connected completely and can be discarded.

Scheme 48

FUEL LINE CONNECTORS (MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626)

Note. On fuel hose where 2 clamps are used, position clamp tabs more than 45 degrees apart. Ideally, clamps should be positioned 180 degrees apart.

Disconnect & Connect - Tabless Design (Miata, Protege, Protege5 & 626)

Note. If Special Service Tool (SST) is not used to release fuel line, effectiveness of quick release retainer is reduced. Quick release retainer must be replaced. For correct SST, see QUICK RELEASE CONNECTOR TOOL APPLICATION table. (Scheme 49)

Clean quick release connector. Press SST into quick release connector and pull connector apart. For correct SST, see QUICK RELEASE CONNECTOR TOOL APPLICATION table. (Scheme 49) 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.

Scheme 49

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.

QUICK RELEASE CONNECTOR TOOL APPLICATION

FUEL SYSTEM PRIMING

Miata, Millenia, Protege & Protege5

Connect fused jumper wire between F/P terminal of Data Link Connector (DLC-1) and ground. (Scheme 50) Turn ignition switch on for about 5 minutes. Inspect for leakage at fuel hoses, clamps and pipe sealing surfaces. If leaks are found, turn ignition switch off. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Repair or replace components as necessary and retest fuel system. If no leaks are found, turn ignition switch off and disconnect fused jumper wire.

Scheme 50

Disconnect negative battery cable. Remove fuel pump relay from underhood main relay box. Connect fused jumper wire between ground and fuel pump relay socket terminal No. 30. (Scheme 51) Reconnect negative battery cable for about 5 minutes. Inspect for leakage at fuel hoses, clamps and pipe sealing surfaces. If leaks are found, turn ignition switch off. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Repair or replace components as necessary and retest fuel system. If no leaks are found, disconnect negative battery cable and then fused jumper wire.

Scheme 51

FUEL PUMP

FUEL PRESSURE REGULATOR

FUEL RAILS & INJECTORS

CHARCOAL CANISTER

CHARCOAL CANISTER LOCATION

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)

TORQUE SPECIFICATIONS (MPV)

PROTEGE, PROTEGE5 & 626 2.0L

TORQUE SPECIFICATIONS (PROTEGE, PROTEGE5 & 626 2.0L)

TORQUE SPECIFICATIONS (TRIBUTE)