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Walkthru on coil replacement for 2002-
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bubba
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PostPosted: Sat Jul 28, 2007 7:02 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

We know head around to the the back of the engine where much of the work is unfortunately done by braille!!



Remove P/S hose from bracket and pull off of manifold to IMCC area. Remove Red 8mm bolt for support bracket. Disconnect both vaccum hoses (large lower one is the infamous PCV hose that ruptures) and pull EGR harness away from manifold as shown left.
IMG_1471_2_1.JPG

IMG_1471_2_1.JPG - File downloaded or viewed 91131 time(s)

Remove the two 12mm bolts securing the EGR valve and make sure not to loose the thin metal gasket that will fall out. Disconnect the IAC valve connector on top and TP sensor connector on the bottom. Disconnect harness from throttle body stud at bottom.
IMG_1473_3_1.JPG

IMG_1473_3_1.JPG - File downloaded or viewed 70626 time(s)

If have 2004 or later then make a quick jump to last picture for coolant hose removal. Come back to this step when done. 2002-2003 just keep going. Now remove the six 8mm bolts that hold the intake manifold down.
IMG_1447_1_1.JPG

IMG_1447_1_1.JPG - File downloaded or viewed 69879 time(s)

Now lift the throttle body side of the intake manifold and remove the two clamps and both of these vacuum lines.
IMG_1479_1_1_1.JPG

IMG_1479_1_1_1.JPG - File downloaded or viewed 69829 time(s)

Intake manifold will now come right out of engine compartment and have open access to those pesky rear coils and plugs.
IMG_1476_1_1.JPG

IMG_1476_1_1.JPG - File downloaded or viewed 69675 time(s)



Last edited by bubba on Mon Oct 22, 2007 6:26 pm; edited 6 times in total
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bubba
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PostPosted: Sat Jul 28, 2007 7:12 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Final pic and then you can enjoy a sip of that hopefully still cold beer.

While the manifold and throttle body is off it would be a very good idea to invest in a couple can of carb cleaner and spray off as much of that black gook built up inside the manifold as possible. Also clean out the area of the throttle body where the throttle plate is located to prevent future throttle sticking problems. DO NOT use a wire brush inside the throttle body as you will cause more damage then help things. Use an old stiff bristle toothbrush. Have found that to work about the best.

A few notes on reassembly. Once the intake manfold has been reinstalled then very loosely install the six 8mm bolts that hold it down. Make sure manifold is still loose and easily moved. Now install the bolts and gasket for the EGR valve. Run up to finger tight and then back off a full turn. Do this same thing to the small 8mm bolts for the manifold support brackets just below the EGR valve and on back of engine near power steering bracket. These bolts can be a bugger to get a thread started once manifold has been fully tightened down so by getting them almost fully installed prior to tightening manifold you will eliminate a considerable amount of hair pulling and turning the air blue #@$%$#&^!. Also make sure that the small black harness bracket on right rear corner of manifold below the IMCC has not gotten trapped under the manifold as it always seems to want to do that.

Torque Specs :

Intake manifold bolts...72-105 in/lbs or 6-9 ft/lbs
EGR valve bolts........165-225 in/lbs or 14-19 ft/lbs
Remaining little bolts for brackets, etc......72-95 in/lbs or 6-8 ft/lbs




Here are the grand total of bolts that were needed removed to do the job. Not as bad as you thought eh??
IMG_1442_1_1.JPG

IMG_1442_1_1.JPG - File downloaded or viewed 68564 time(s)

For 2004 and later only, Remove these two small coolant hoses on either side of Throttle Body then head back up and continue manifold removal.
7 006 (Small).jpg

7 006 (Small).jpg - File downloaded or viewed 67986 time(s)



Last edited by bubba on Thu Jan 17, 2008 7:24 pm; edited 2 times in total
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subearu
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PostPosted: Sat Jul 28, 2007 8:15 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Sweet photo documentation! I made your post a sticky, so it will be up at the top of the problems thread.

Sure makes it look easy enough. If I have to ever do this on our '02, why don't you stop by for a brew or two. Wink drink

-Brian

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rollie1960
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PostPosted: Sat Jul 28, 2007 9:43 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Bubba nice pictures and write up would it be smart to replace some water hoses now that one is there or PVC and hose and so on your the man what do you think? Also when are you coming to Houston, Tx I would sure like for you to tackle some work on the DW 2001 MPV I agree you make it look so easy.
Take care! Rollie Smile
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cpapashley
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PostPosted: Sun Jul 29, 2007 4:38 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Wonderful Sticky there Bubba,

makes it look very dooable for those about to set out on DIY under the hood of their MPV's.... Very Happy

Gives a great view of those oval ports too...which makes me wonder do the 3.0l injectors fit in the 2.5l?? just thinking ahead for when I finally get this emanage unit on the car... Smile

2000 MPV Seychelles Green 279,000 km
Custom Cold Air Intake, K&N Panel Filter
Custom Equal Length Headers and Y pipe
Hi Flow CAT, 2 1/2" with straight through exhaust....ohhhh it makes you smile......
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bubba
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PostPosted: Tue Jul 31, 2007 2:34 am    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

It really is as easy as it looks in the pics. Just a matter of getting the right bolts and hoses, etc undone and manifold will come right out. No coolant hoses that will be more easily replaced later on rollie1960. Getting the updated PCv hose AJ51-13-89YB replaced would be a very good idea indeed given the growing number of problems that are coming out.
Follow the steps and you can have that manifold in and out in no time. I actually do not remove the manifold in full and leave out some of the steps but instead just pull the manifold out enough to get to the coils. Thought that the full remove would be better for DIY as does not take that much more to do and was afraid that steps I use might lead to some damaged connectors or wiring or PCV hose yanked out that would cause more problems and much more of the #^$%$&$^%^ screw you bubba posts. It does work and can be done in an hour or two for the DIY'er.
If am ever in the WI or TX area would be happy to stop in and share a cold one with you guys Thanks for the invitation for the cold one and is very tempting. Would rather go visit Ashley in Australia as that as been my dream vacation to go see the land down under.
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lgoolsby
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PostPosted: Tue Jul 31, 2007 10:13 am    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Bubba,

Great tutorial there though I really wish this had been posted a day or two earlier. I replaced my rear coils and PCV tube on Saturday using the other photo illustration found here. I had planned on it being a 2 - 4 hours job but turned into a 10 hours day. 10 hours... what went wrong. Well, I have 4 children and a wife that was called into work. Also I had ordered the Coils from Autozone ($46 each) only to find out Friday evening when I went to pick up that the order was canceled due to no stock (sure would be nice to get a phone call.) Thus, I had to drive to Mazda dealership across town to buy (at $78 a piece) the coils. Then, I found the PCV tube connector behind the manifold was cracked wide open (thus the real cause of my problem. Not wanting to drive back to mazda I visited the FORD dealership up the road and found a match.

Having done this once, I have no doubt I could do it again in 2 hours pending I had all the required parts sitting beside my of cold beers. If I can do it then anybody can do it. Never have i done anything mechanical to a vehicle. Lets just say that I have a real sense of accomplishment and a few hundred dollars saved. I now plan on doing much more maintenance on my own so thanks to all those here that give such great help.

Oh, did I say that I have one bolt left over. Is that bad??? No, really I was unable to get the rear bracket bolt back in and so I need to loosen everything back up tonight and work at it.
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lgoolsby
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PostPosted: Tue Jul 31, 2007 10:17 am    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Forgot to ask... What is the trick to getting the intake boot off? Yes, I loosened the clamps. I was able to get it off of the AIR FILTER side but not from the Manifold. Even when the manifold was removed, I could not get it off. Just made removing and reinstalling the manifold slightly trickier.

As a side note, what is the typical price of havng sparkplugs changed at a dealership?
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cpapashley
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PostPosted: Wed Aug 01, 2007 4:56 am    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

lgoolsby wrote:
Bubba,

Great tutorial there though I really wish this had been posted a day or two earlier. I replaced my rear coils and PCV tube on Saturday using the other photo illustration found here. I had planned on it being a 2 - 4 hours job but turned into a 10 hours day. 10 hours... what went wrong. Well, I have 4 children and a wife that was called into work. Also I had ordered the Coils from Autozone ($46 each) only to find out Friday evening when I went to pick up that the order was canceled due to no stock (sure would be nice to get a phone call.) Thus, I had to drive to Mazda dealership across town to buy (at $78 a piece) the coils. Then, I found the PCV tube connector behind the manifold was cracked wide open (thus the real cause of my problem. Not wanting to drive back to mazda I visited the FORD dealership up the road and found a match.

Having done this once, I have no doubt I could do it again in 2 hours pending I had all the required parts sitting beside my of cold beers. If I can do it then anybody can do it. Never have i done anything mechanical to a vehicle. Lets just say that I have a real sense of accomplishment and a few hundred dollars saved. I now plan on doing much more maintenance on my own so thanks to all those here that give such great help.

Oh, did I say that I have one bolt left over. Is that bad??? No, really I was unable to get the rear bracket bolt back in and so I need to loosen everything back up tonight and work at it.


Shocked ah yes four children.....oh the joys Very Happy

I tend to expect most jobs to take a full day. I usually start in the morning and it inevitably lasts until sundown...... Wink

I think you did well tackling the job lgoolsby, and btw welcome to the forum.

Also seeing I have the earlier model cannot comment on that inlet tubing, mine comes off very easy. There is a special tool used to just ease off the coolant tubes/hoses don't know what the name is but just seems to break the seal and make the job of removing coolant hoses very easy, might work with the inlet tubing.

Wonder if it gets hotter due to the positioning??

2000 MPV Seychelles Green 279,000 km
Custom Cold Air Intake, K&N Panel Filter
Custom Equal Length Headers and Y pipe
Hi Flow CAT, 2 1/2" with straight through exhaust....ohhhh it makes you smile......
MPV Club Sticker to finish off the package


Last edited by cpapashley on Wed Aug 01, 2007 5:05 am; edited 1 time in total
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cpapashley
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PostPosted: Wed Aug 01, 2007 5:02 am    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

bubba wrote:
It really is as easy as it looks in the pics. Just a matter of getting the right bolts and hoses, etc undone and manifold will come right out. No coolant hoses that will be more easily replaced later on rollie1960. Getting the updated PCv hose AJ51-13-89YB replaced would be a very good idea indeed given the growing number of problems that are coming out.
Follow the steps and you can have that manifold in and out in no time. I actually do not remove the manifold in full and leave out some of the steps but instead just pull the manifold out enough to get to the coils. Thought that the full remove would be better for DIY as does not take that much more to do and was afraid that steps I use might lead to some damaged connectors or wiring or PCV hose yanked out that would cause more problems and much more of the #^$%$&$^%^ screw you bubba posts. It does work and can be done in an hour or two for the DIY'er.
If am ever in the WI or TX area would be happy to stop in and share a cold one with you guys Thanks for the invitation for the cold one and is very tempting. Would rather go visit Ashley in Australia as that as been my dream vacation to go see the land down under.


Always welcome downunder, best time to come in my neck of the woods is autumn through to spring (for us that is March through to October). Summer ( November through to February) can tend to be a little hot and humid...

But always plenty of beer downunder to satisfy those who have a thrist... Wink

2000 MPV Seychelles Green 279,000 km
Custom Cold Air Intake, K&N Panel Filter
Custom Equal Length Headers and Y pipe
Hi Flow CAT, 2 1/2" with straight through exhaust....ohhhh it makes you smile......
MPV Club Sticker to finish off the package
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Tomas
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PostPosted: Tue Aug 07, 2007 8:28 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

AWESOME JOB! Makes me think I can change the plugs w/o paying a high priced mechanic now Laughing
2009 Mazda5 Sport
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gadkins
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Location: Clifton Park, New York, United States of America

PostPosted: Thu Sep 27, 2007 3:13 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

I found this powerpoint buried on this site some where.

http://www.theorchardchurch.net/temp/MazdaPlugChange.ppt
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breatherguy
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PostPosted: Tue Oct 09, 2007 5:07 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Bubba:

You are the best!

I did the coil replacement yesterday will little trouble. I found the coils at http://www.autopartsworld.com for $56 each.
Thank you!

Breather Guy
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trfcrx7
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PostPosted: Tue Oct 30, 2007 11:08 am    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Just a note to those who choose not to do the work themselves. I just had the No. 1 coil replaced at the dealer on my 2004:

$62.35 for the Coil
$16.98 for 6 New Spark Plugs
$160 for Labor
$239.33 Total

So, the cost would likely be the same to replace a coil on the rear bank of cylinders. Anyway, that should give you some idea of whether you want to do the work yourself or not.

By the way, what Bubba provided is why this forum is so great. Thanks.

Brad.

2004 MPV LX w/ Tow Package (DW Commuter)
2001 MP3 in Vivid Yellow (Commuter)
1990 RX-7 (My Play Vehicle)
1998 Tahoe 2-Door (Tow Vehicle and yank tractor out of mud vehicle)
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z00m
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PostPosted: Wed Nov 14, 2007 12:22 pm    Post subject: Re: Walkthru on coil replacement for 2002- Reply with quote

Well wait till you need to do this 5 times more, and see if your blood starts to boil over for all the hassles and expenses involved.
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