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

Removal & Installation (B2300, B3000, B4000 & Tribute)

1. Disconnect negative battery cable. Disconnect Throttle Position (TP) sensor harness connector. Remove splash shield (if equipped) to expose throttle linkage.
2. Disconnect throttle cable and cruise control cable (if equipped) from throttle lever on throttle body. Remove air cleaner-to-throttle body air inlet tube. Disconnect canister purge hose from fitting beneath throttle body.
3. Remove 4 throttle body bolts. Remove throttle body from upper intake manifold. Install NEW throttle body gasket. To complete installation, reverse removal procedure. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) .

Removal & Installation (Miata, Millenia, MPV, Protege, Protege5 & 626)

Disconnect negative battery cable. Remove air cleaner (if necessary). Remove air intake tubes. Disconnect accelerator cable, coolant hoses and harness connectors from throttle body as necessary. Remove throttle body. To install, reverse removal procedure using NEW throttle body gasket. See TORQUE SPECIFICATIONS .

Removal (B2300)

1. Disconnect negative battery cable. Disconnect Throttle Position (TP) sensor, Manifold Absolute Pressure (MAP) sensor and Idle Air Control (IAC) valve. Remove air cleaner outlet tube. Remove splash shield and disconnect accelerator and cruise control (if equipped) cable(s). Disconnect harness connectors, vacuum hoses and vapor hose from throttle body.
2. Disconnect vacuum and wiring harnesses and position out of way. Disconnect and plug coolant hose from intake manifold. Disconnect fuel line from retainer clip. Remove electronic EGR tube and valve. Disconnect Knock Sensor (KS). Disconnect Power Steering (P/S) pump reservoir and position out of way. Evenly loosen 5 bolts and remove upper intake manifold.

Inspect intake manifold gasket and replace if necessary. Install intake manifold and 5 mounting bolts. Tighten bolts evenly to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (B3000)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect throttle return spring. Disconnect accelerator and cruise control (if equipped) cable(s) from throttle body lever.
2. Disconnect harness connectors from Throttle Position (TP) sensor and Idle Air Control (IAC) valve. Disconnect brake booster vacuum hose from upper intake manifold.
3. Loosen bolt on 42-pin harness connector, disconnect harness from bracket and position harness out of way. Disconnect evaporative emissions hose. Disconnect heater hoses from intake manifold.
4. Remove PCV valve from valve cover. Remove upper bolt and loosen lower nut from manifold support bracket. Remove bolt and move EGR vacuum regulator valve out of way. Remove upper intake manifold.

Reinstall upper intake manifold using NEW gasket. Tighten upper intake manifold bolts evenly in sequence and 2 passes. (Scheme 1) Tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 1

Removal & Installation (B4000)

1. Disconnect negative battery cable. Remove air cleaner outlet pipe. Disconnect accelerator and cruise control (if equipped) cable(s) from throttle body lever. Remove accelerator cable bracket.
2. Disconnect harness connectors from Throttle Position (TP) sensor, Idle Air Control (IAC) valve and EGR valve vacuum regulator. Disconnect EGR pipe. Disconnect Power Control Module (PCM) harness connector, wire harness support and ground terminal. Move harness aside.
3. Disconnect brake booster and vacuum hoses from upper intake manifold and throttle body. Disconnect ignition coil harness connector, right hand secondary ignition wires and unbolt coil. Evenly loosen upper intake manifold nuts. Lift intake manifold and disconnect heated PCV fitting from manifold.
4. To install, replace upper intake manifold gasket (if necessary). Install upper intake manifold and bolts. Tighten in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) . To complete installation, reverse removal procedure.

Removal & Installation (Miata)

1. Disconnect negative battery cable. Drain coolant. Remove air cleaner outlet tube. Disconnect accelerator and cruise control (if equipped) cable(s) from throttle body. Remove upper manifold bracket.
2. Disconnect PCV and vacuum hoses from upper intake manifold. Disconnect harness connectors from Throttle Position (TP) sensor and Idle Air Control (IAC) valve. Disconnect and plug coolant hoses from throttle body. Evenly loosen upper intake manifold bolts and remove manifold.
3. To install, replace upper intake manifold gasket (if necessary). If replacing upper intake gasket, position gasket with raised side toward lower intake manifold. (Scheme 2) Install upper intake manifold bolts and tighten in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000). To complete installation, reverse removal procedure.

Scheme 2

Removal & Installation (Millenia 2.3L)

1. Disconnect negative battery cable. Remove dynamic chamber cover. Remove Charge Air Cooler (CAC) air duct and air cleaner assembly. Remove fresh air duct and connecting air duct. Remove Mass Airflow (MAF) sensor and air intake hose.
2. Remove air resonator. Remove right and left CACs with connecting hoses (if needed) from air intake pipe assembly. Disconnect accelerator cable. Remove EGR valve. Disconnect vacuum lines and harness connector from upper intake manifold assembly. Remove upper intake manifold assembly.
3. To install, replace upper intake manifold gasket (if necessary). Install upper intake manifold bolts/nuts and tighten in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) . To complete installation, reverse removal procedure.

Removal & Installation (Millenia 2.5L, MPV & 626 2.5L)

1. Disconnect negative battery cable. Drain engine coolant. Remove air cleaner, Mass Airflow (MAF) sensor and inlet hose. Remove throttle body coolant hoses. Disconnect harness connectors and vacuum hoses from throttle body and upper intake manifold.
2. Disconnect EGR valve pipe on Millenia only. Disconnect line and harness brackets.
3. Evenly loosen upper intake manifold bolts/nuts. To install, replace upper intake manifold gasket (if necessary). Install upper intake manifold bolts/nuts and tighten in crisscross pattern to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) . To complete installation, reverse removal procedure.

Removal & Installation (Tribute 3.0L)

1. Remove air cleaner outlet tube. Remove engine appearance cover. Disconnect throttle and cruise control (if equipped) cable(s) and bracket.
2. Disconnect EGR vacuum hose and pipe. Disconnect EGR vacuum regulator valve harness connector and vacuum hose. Mark location and disconnect chassis, engine, PCV and vapor management valve vacuum hoses. Disconnect 2 harness connectors attached to left side of upper intake manifold.
3. Disconnect Power Steering Pressure (PSP) sensor harness connector. Remove bolt and bracket for transaxle vent hose. Remove all 8 upper intake manifold bolts. Remove upper intake manifold. To install, reverse removal procedure. Inspect gaskets and replace if damaged. Tighten upper intake manifold bolts in sequence. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000).

Scheme 3

Disconnect negative battery cable. On Tribute models, remove PCM cover. On all models, disconnect PCM harness connector by loosening bolt. Remove PCM retainer nuts, retainer plate and PCM. To install, reverse removal procedure.

Disconnect negative battery cable. Disconnect PCM harness connector. Remove nut holding PCM wire harness. Push PCM wire harness away from brake pedal bracket. Hold harness away and remove nut holding PCM. Remove PCM. To install, reverse removal procedure.

Removal & Installation (Millenia)

Disconnect negative battery cable. Remove rear console, shifter panel and center dash panel. Remove nuts from front and left side of PCM. Loosen PCM. Remove dashboard undercover. Separate rear heater ducts on both sides behind PCM. Disconnect PCM harness connectors and remove PCM. To install, reverse removal procedure.

Removal & Installation (MPV)

Disconnect negative battery cable. Remove glove compartment. Disconnect blower resister from top of air duct and remove air duct. Remove PCM cover panel. Loosen bolt and disconnect PCM harness connector. Remove PCM. To install, reverse removal procedure.

Removal & Installation (Protege & Protege5)

Disconnect negative battery cable. Remove passenger scuff plate and side trims. Pull passenger carpet back away from PCM. Remove PCM cover panel. Loosen bolt and disconnect PCM harness connector. Remove nuts holding PCM brackets to cover panel and remove PCM. To install, reverse removal procedure.

Removal & Installation (626)

Disconnect negative battery cable. Remove shifter knob (MTX). Remove center dash panel. Remove front console. Remove rear console assembly. Loosen bolt and disconnect PCM harness connector. Remove bolts under PCM. Remove PCM. To install, reverse removal procedure.

Removal & Installation (B2300)

Camshaft Position (CMP) sensor is mounted on top of valve cover at rear. (Scheme 4) Disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove CMP sensor mounting bolt. Remove CMP sensor. To install, reverse removal procedure.

Scheme 4

Removal & Installation (B3000)

Camshaft Position (CMP) sensor is located on rear of engine, behind intake manifold. (Scheme 5) Before removing, note position of harness connector on CMP sensor. Disconnect negative battery cable. Remove upper intake manifold. See REMOVAL (B3000) under UPPER INTAKE MANIFOLD. Disconnect CMP sensor harness connector. Remove CMP sensor screws and CMP sensor. To install, reverse removal procedure. Ensure CMP sensor harness connector is pointing in original direction. Tighten CMP sensor to specification. See TORQUE SPECIFICATIONS.

Scheme 5

Locate Camshaft Position (CMP) sensor in left valve cover. (Scheme 6) Disconnect CMP sensor harness connector. Remove bolt. Remove CMP sensor. To install, reverse removal procedure.

Scheme 6

Removal & Installation (Miata, Millenia 2.3L, MPV, Protege, Protege5 & 626 2.0L)

On Miata, Camshaft Position (CMP) sensor is located on rear of cylinder head. On Millenia 2.3L, MPV, Protege, Protege5 and 626 2.0L, CMP sensor is located on front of valve cover. To remove, disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove hold-down bolt. (Scheme 7) Remove CMP sensor. To install, reverse removal procedure. Tighten bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 7

Removal & Installation (Tribute)

Locate Camshaft Position (CMP) sensor (On 2.0L, sensor is located at left front of cylinder head. On 3.0L, sensor location is located on front of left cylinder head). (Scheme 7)and (Scheme 8). To remove, disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove bolt. Remove sensor. To install, reverse removal procedure.

Scheme 8

Removal & Installation (626 2.5L)

Camshaft Position (CMP) sensor is located behind camshaft pulley. Disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove timing belt cover and timing belt. Remove rear valve cover. Hold cast hexagonal part intake camshaft with an adjustable end wrench or equivalent and loosen camshaft pulley bolt. (Scheme 9) Remove bolt and camshaft pulley. Remove CMP sensor. To install, reverse removal procedure.

Scheme 9

Removal & Installation (Except B2300, Miata & Tribute 2.0L)

Disconnect negative battery cable. Crankshaft Position (CKP) sensor is located on front of engine, near crankshaft pulley. (Scheme 10)- (Scheme 15). Remove engine undercover. Disconnect CKP harness connector. Remove sensor bolts and sensor. On Protege and Protege5 models only, some adjustment is possible. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Disconnect negative battery cable. Crankshaft Position (CKP) sensor is located at front of engine near crankshaft pulley. (Scheme 16) Disconnect CKP sensor harness connector. Remove plug (bolt) for Crankshaft Timing Peg (303-507). (Scheme 17) Install Crankshaft Timing Peg and turn crankshaft pulley to Top Dead Center (TDC). (Scheme 18) Remove CKP sensor. Install Timing Pin. (Scheme 19)

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Installation (B2300)

Install Crankshaft Position (CKP) sensor, but do not tighten mounting bolts. Adjust CKP sensor with Crankshaft Position Sensor Alignment Jig and tighten bolts to specification. (Scheme 20) See TORQUE SPECIFICATIONS. Connect CKP sensor harness connector. Remove Timing Pin. Remove Crankshaft Timing Peg and reinstall plug (bolt).

Scheme 20

Disconnect negative battery cable. Crankshaft Position (CKP) sensor is located on front of engine, near crankshaft pulley. Remove engine compartment undercover. Disconnect CKP sensor harness connector. Remove bolts and CKP sensor. To install, replace CKP sensor and loosely install mounting bolts. Using a feeler gauge, adjust sensor air gap to .020-.059" (.5-1.5 mm). If air gap is still not within specification, replace crankshaft pulley or CKP sensor. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (Tribute 2.0L)

Disconnect negative battery cable. Disconnect catalytic converter from exhaust manifold. Remove oil dipstick and tube. Remove 6 bolts and 3 nuts and remove exhaust manifold. Disconnect Crankshaft Position (CKP) sensor harness connector. Remove bolt and CKP sensor. To install, reverse removal procedure using a NEW exhaust manifold gasket. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Disconnect Heated Oxygen Sensor (HO2S) harness connector. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). If HO2S is difficult to remove, use rust penetrant to avoid damaging threads. Using appropriate HO2S socket, carefully remove sensor.

Apply anti-seize to sensor threads (if reusing old sensor or if new sensor is not coated with anti-seize). Install HO2S and tighten to specification. See TORQUE SPECIFICATIONS . Reconnect sensor harness connector.

Disconnect negative battery cable. Remove intake manifold bracket, located on right side of engine. Disconnect Knock Sensor (KS) harness connector. Using tool (49-H018-001), remove and install sensor. (Scheme 21) To complete installation, reverse removal procedure.

Scheme 21

Knock Sensor (KS) is located under Lysholm compressor, between cylinder banks. See LYSHOLM COMPRESSOR (MILLENIA 2.3L) for removal and installation procedure of Lysholm compressor. Disconnect KS harness connector. Use tool (49-H018-001) to remove and install KS. (Scheme 21) To complete installation, reverse removal procedure. When installing (KS), fit harness into drill hole on cylinder block. Pass harness under rubber insulator on left cylinder head. (Scheme 22)

Scheme 22

Removal & Installation (Millenia & 626 2.5L)

Knock Sensor (KS) is located under upper intake manifold, between cylinder banks. See UPPER INTAKE MANIFOLD for removal and installation procedure of upper intake manifold. Disconnect KS harness connector. Use tool (49-H018-001) to remove and install KS. (Scheme 21) To complete installation, reverse removal procedure.

Removal & Installation (B2300, B3000, B4000, MPV & Tribute)

Knock Sensor (KS) is located on right side of engine block. Disconnect KS harness connector and remove from mounting bracket. Remove bolt (nut on Tribute 2.0L) and KS. To install reverse removal procedure.

Removal & Installation (Protege, Protege5 & 626 2.0L)

Note. May require removing oil filter first.

Knock Sensor (KS) is located above oil filter. Disconnect KS harness connector. Use tool (49-H018-001) to remove and install KS. (Scheme 21)

Removal & Installation

Disconnect negative battery cable. Reference mark high tension wires to distributor cap and disconnect. Disconnect both harness connectors from distributor. Remove 3 screws and distributor cap. Remove hold-down bolt and distributor. To install, reverse removal procedure using NEW "O" ring. Apply oil to "O" ring before installation. Adjust ignition timing. See MIATA, MILLENIA, MPV, PROTEGE & PROTEGE5 under IGNITION TIMING in ON-VEHICLE ADJUSTMENTS article.

Internal parts are not available. If faulty, replace complete distributor. Only cap, rotor and "O" ring are available. (Scheme 23)

Scheme 23

Each ignition coil has an integral control module. To remove coil(s) on front cylinder head, remove Charge Air Cooler (CAC). To remove coil(s) on rear cylinder head, remove solenoid bracket. On all coils, disconnect 4-pin harness connector. Remove mounting bolt and coil assembly. To install, reverse removal procedure.

Removal & Installation (Millenia 2.5L)

Ignition control module is integrated with distributor and is not serviced separately, replace complete distributor assembly.

Note. A primary suction side sock/strainer is attached to the fuel pump pick-up located inside the fuel tank. The main high pressure side filter is located on top of the fuel tank and is accessed through the trunk via an access panel.

Scheme 24

1. Disconnect negative battery cable. Remove 3 screws from fuel tank access panel in trunk.
2. Disconnect fuel hoses from fuel filter. Remove fuel filter and bracket.
3. To install, reverse removal procedure. Ensure fuel hoses are pushed completely onto filter nozzles.
4. Reconnect negative battery cable. Check for leaks.

Scheme 25

1. Relieve the system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000)
2. Disconnect the negative battery cable.
3. Remove fuel pump assembly. Remove the necessary components and the fuel filter. (Scheme 25)
4. Install in the reverse order of removal.
5. Verify that the fuel hoses are are properly connected.
6. Reconnect negative battery cable. Test for leaks.

Scheme 26

1. Relieve the system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000).
2. Disconnect the negative battery cable.
3. Raise the rear of the vehicle and support it with safety stands.
4. Remove the fuel filter protector.
5. Remove in the order indicated in (Scheme 26).
6. Install in the reverse order of removal.
7. Reconnect negative battery cable. Check for leaks.

Removal & Installation (Protege)

Note. Fuel filter is located in fuel tank as an attachment on fuel pump assembly.

1. Relieve the system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000)
2. Disconnect the negative battery cable.
3. Remove fuel pump assembly. Remove the necessary components and the fuel filter. see scheme 36
4. Install in the reverse order of removal.
5. Verify that the fuel hoses are are properly connected.
6. Reconnect negative battery cable. Test for leaks.

1. Relieve the fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000).
2. Disconnect the battery ground cable.
3. Loosen the clamp and remove the fuel filter. see scheme 37
4. Install replacement fuel filter.
5. Install new fuel line clips.To install, reverse the removal procedure.
6. Check for fuel leaks.

Disconnect - Spring Lock Coupling

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000). Remove locking (safety) clip (if equipped). Place Spring Lock Coupling Releaser (49-UN01-051) for 3/8" line, 49-UN01-052 for 1/2" line) over fuel line coupler. see scheme 38
2. Push spring lock coupling releaser toward garter spring to separate coupling. Pull spring lock coupling apart. Remove releaser.

Removal (B2300, B3000 & B4000)

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove fuel tank. Clean area around fuel pump mounting flange. Turn fuel pump sending unit lock ring counterclockwise using Fuel Sender Wrench (310-069). (Scheme 27) Remove lock ring. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Scheme 27

Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise using Fuel Sender Wrench (310-069). See TORQUE SPECIFICATIONS . Install fuel tank.

Removal (Miata)

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove rear package trim. Remove fuel pump access cover. Disconnect both fuel hoses and 4-pin harness connector. See QUICK RELEASE CONNECTOR TOOL APPLICATION table. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Install fuel pump into sending unit assembly. Pull fuel pump down so that it is flush against bracket on sending unit. To complete installation, reverse removal procedure.

Removal (Millenia)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel tank. Disconnect both fuel lines and 4-pin harness connector from sending unit assembly. Using Fuel Sender Wrench (49-U014-001), turn locking retainer ring counterclockwise. (Scheme 28) Remove lock ring. Remove fuel pump and sending unit assembly.

Scheme 28

Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise using Fuel Sender Wrench (49-U014-001). To complete installation, reverse removal procedure.

Removal (MPV)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Remove front seats. Remove front and rear scuff plates. Remove console lower cover. Loosen parking brake lever installation bolts. Peel back the carpeting until access service cover is accessible. Remove cover. Disconnect 4-pin harness connector and both fuel lines. Remove fuel pump and sending unit assembly. Remove fuel pump from sending unit assembly.

Using NEW seal and fuel filter retainer washer, install fuel pump in sending unit assembly. Install fuel pump and sending unit assembly into fuel tank using NEW gasket. (Scheme 29) Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 29

Removal (Protege & Protege5)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Remove rear seat cushion. Remove fuel pump access cover. Disconnect 4-pin harness connector and both fuel lines. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Install fuel pump into sending unit assembly using NEW seal and fuel filter retainer washer. Install fuel pump and sending unit assembly into fuel tank using new gasket. (Scheme 29) Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Removal (Tribute)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Lift left rear seat cushion. Remove carpet retainers, and position carpet aside. Remove fuel pump access cover screws and access cover. Disconnect harness connector. Disconnect fuel and vapor lines from fuel tank. Using Fuel Sender Wrench (310-069), remove lock ring and fuel pump module. (Scheme 27)

Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise using Fuel Sender Wrench (310-069). See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (626)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Disconnect harness connector. Disconnect fuel lines, fuel filler pipe and EVAP hoses. Clean fuel line connectors. Use quick release connector tool to remove fuel lines. See QUICK RELEASE CONNECTOR TOOL APPLICATION table. Disconnect Fuel Tank Pressure (FTP) sensor. Remove presilencer protector. Remove fuel tank straps. Remove fuel tank. Remove fuel pump assembly.

Note. Fuel gauge unit may be replaced separately from fuel pump assembly.

Clean gasket surface on fuel tank. Use NEW gasket. Install fuel pump assembly into fuel tank. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure fittings are clean before connecting fuel lines to fuel pump fittings. To complete installation, reverse removal procedure.

Removal & Installation (B2300, B3000, B4000, Miata, MPV & Tribute)

On returnless systems, regulator is inside fuel tank. On all models except Miata, pressure regulator is an integral part of fuel pump. On Miata, pressure regulator is mounted to fuel pump and sending unit assembly and may be replaced seperately. (Scheme 30) See appropriate procedure under FUEL PUMP.

Scheme 30

Removal & Installation (Millenia, Protege, Protege5 & 626)

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000) .
2. Disconnect vacuum and fuel hose(s) from regulator. Remove regulator mounting bolts. Remove regulator and "O" ring from fuel rail.
3. To install, reverse removal procedure. Using NEW "O" ring. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) .

Note. Do not use silicone grease to lubricate "O" rings. May clog fuel injectors.

Note. Install fuel injectors with slight twisting motion to prevent "O" rings from folding.

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. On models except Tribute 2.0L, remove upper intake manifold. See appropriate procedure under UPPER INTAKE MANIFOLD. On Tribute 2.0L, remove air cleaner outlet pipe. Disconnect fuel lines with spring lock coupling releaser. see scheme 38 Disconnect vacuum hose to fuel pulse damper. Disconnect fuel injector harness connectors. Remove fuel rail bolts and fuel rail(s). Remove injectors from fuel rails. Inspect injector "O" ring seals. If damaged, replace with NEW "O" rings. Coat "O" rings with motor oil and install on injectors. To complete installation, reverse removal procedure.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000) . Disconnect negative battery cable. Remove air hose and upper intake manifold. See «UPPER INTAKE MANIFOLD»(ref-134974-S14353278652002022100000) . Disconnect fuel hoses from fuel rail. See «FUEL LINE CONNECTORS (MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626)»(ref-134974-S30411040632002022100000) . Disconnect fuel injector harness connectors. Remove fuel rail and injectors as an assembly. Remove insulators, injectors, pulsation damper No. 2 and "O" rings from fuel rail.
2. Install New injector insulators. Ensure insulators are pressed in fully and not twisted or bent. Apply coating of engine oil to NEW "O" rings, and install on fuel injectors and pulsation damper No. 2. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) . Install NEW extension manifold gasket. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000) . Remove dynamic chamber cover. Remove air intake ducts and air cleaner assembly.
2. Remove left and right Charge Air Coolers (CAC). Remove air intake pipes. Disconnect accelerator cable. Disconnect fuel injector harness connectors. Disconnect vacuum and fuel hoses. See «FUEL LINE CONNECTORS (MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626)»(ref-134974-S30411040632002022100000) . Remove fuel rail, injectors and pressure regulator as an assembly.
3. Remove insulators, injectors and "O" rings from fuel rail. To install, reverse removal procedure. Install NEW injector insulators. Ensure insulators are pressed in fully and not twisted or bent. Apply coating of engine oil to NEW "O" rings and install on fuel accumulator, fuel injectors and fuel pressure regulator. Ensure injector alignment tab is aligned to notch in fuel rail. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) .

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000) . Disconnect negative battery cable. Remove upper intake manifold and throttle body as an assembly. See «UPPER INTAKE MANIFOLD»(ref-134974-S14353278652002022100000) . Disconnect vacuum and fuel hoses from fuel rail. See «FUEL LINE CONNECTORS (MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626)»(ref-134974-S30411040632002022100000) . Disconnect fuel injector harness connectors. Remove fuel rail, accumulator, fuel injectors and pressure regulator as an assembly. Remove accumulator, fuel injectors and pressure regulator from fuel rail.
2. To install, reverse removal procedure. Apply coating of engine oil to NEW "O" rings and install on accumulator, fuel injectors and pressure regulator. Install accumulator, fuel injectors and pressure regulator into fuel rails. Ensure injector alignment tab is aligned to notch in fuel rail. Ensure insulators are pressed in fully and not twisted or bent. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) .

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-134974-S37972993292002022100000) . Disconnect fuel line. See «FUEL LINE CONNECTORS (MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626)»(ref-134974-S30411040632002022100000) . Disconnect fuel injector harness connectors. Remove injector harness from fuel rail. Remove fuel rail mounting bolts. Remove fuel rail, injectors and pressure regulator as an assembly.
2. Remove insulators, fuel injectors, pulsation damper and pressure regulator from fuel rail. To install, reverse removal procedure. Install NEW injector insulators. Ensure insulators are pressed in fully and not twisted or bent. Apply coat of engine oil to NEW "O" rings and install on fuel injectors, pulsation damper and pressure regulator. Ensure injector alignment tab is aligned to notch in fuel rail. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) .

Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Remove pre-silencer pipe assembly. Remove drive shaft. Disconnect emergency brake cable from brake lever to release brake cables from rear calipers. Disconnect rear brake lines from rear calipers. Remove rear suspension assembly. Disconnect hoses to charcoal canister and remove canister. To install, reverse removal procedure. Adjust emergency brake cable and bleed brake system. See BLEEDING BRAKE SYSTEM in appropriate DISC & DRUM article BRAKES .

1. Disconnect negative battery cable.
2. Disconnect Oil Control Valve (OCV) harness connector.
3. Remove bolt and OCV. To install reverse removal procedure.

1. Disconnect negative battery cable.
2. Remove timing belt. See TIMING BELT under REMOVAL & INSTALLATION in appropriate article in ENGINES.
3. Remove 3 bolts holding blind cover and gasket to Variable Valve Timing (VVT) actuator. Remove blind cover and gasket.
4. Hold cast hexagonal part of intake camshaft with an adjustable end wrench or equivalent to prevent the camshaft from rotating, and loosen the lock bolt.
5. To install, rotate camshaft and face knock pin to top position. Align hole in VVT actuator with knock pin on camshaft. Install bolt in end of camshaft. While holding cast hexagonal part of camshaft, tighten VVT actuator bolt to specification. See «TORQUE SPECIFICATIONS»(ref-134974-S32537507672002022100000) . Install blind cover and NEW gasket to VVT actuator. Tighten to specification. To complete installation, reverse removal procedure.