How to Change the Intake Manifold Gasket on a Mazda 626

Written by david marsh
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The intake gasket for the Mazda 626 is located between the intake manifold and the cylinder head. The seal it creates is important because the fuel/air mixture will be altered if air leaks into the system. Intake gaskets are made of metal or a composite material that conforms to the surfaces of both parts. Removal and replacement of parts in order to reach the cylinder head and intake gasket is a time-consuming and therefore expensive process unless you can do it yourself. Instructions in this article cover the 2.0-litre and 2.2-litre engines.

Skill level:

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Things you need

  • Sockets
  • Wrenches
  • Drain pan
  • Screwdriver
  • Pliers
  • Carburettor cleaner

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  1. 1

    Remove the fuel pump relay. It's usually on the driver's side fenderwell. Start the car and allow it to run until it stops. This clears the fuel delivery system of any gasoline.

  2. 2

    Remove the air ducts, the air cleaner assembly, resonance chamber and mass airflow sensor by disconnecting the electrical connector to the mass airflow sensor and loosening the clamps on the air duct. Depending on the type of clamp, use the screwdriver, socket or pliers.

  3. 3

    Remove the cables connecting the throttle and accelerator to the throttle body. Disconnect the fuel lines. Insert rags in the ends of the fuel lines to keep them from leaking.

  4. 4

    Unhook the coolant hoses. Disconnect the idle air control valve and the throttle position sensor. Take off the throttle body after removing the nuts and mounting bolts.

  5. 5

    Use masking tape and a marker to label the vacuum lines on the intake manifold and disconnect the vacuum hoses from the intake manifold. Remove the bolts that hold the upper intake manifold and take off the manifold.

  6. 6

    Disconnect the fuel lines and the fuel rail and plug them with rags. Use masking tape and a marker to label the fuel injector wiring harness connectors and unplug them.

  7. 7

    Take off the intake manifold support bracket. Unbolt the intake manifold and remove it.

  8. 8

    Clean the remnants of the old gasket from both the intake manifold and the cylinder head. Be careful not to let any debris drop into the cylinder head.

  9. 9

    Install the new gasket according to the instructions in the gasket kit. Use sealant if it is recommended.

  10. 10

    Fit the intake manifold onto the cylinder head and tighten the bolts in the pattern and to the torque specified in the gasket kit instructions.

  11. 11

    Reattach the parts that were removed in reverse order. Be careful to attach all of the wires and vacuum tubes to the correct places.

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