On-Vehicle Installation

CAUTION:

When installing the control valve body component, do not put the coupler component in the open space of the separate plate in the control valve body component.
Do not pinch the coupler component between the separate plate and the control valve body component.

Connect the manual valve link and install the control valve body component.

Fig 1: Identifying Separate Plate
Courtesy of MAZDA MOTORS CORP.
Temporarily install the control valve body component with the bolts.
Bolt length (measured from below the head)
1. 31 mm {1.220 in}
2. 17 mm {0.669 in}
3. 21 mm {0.827 in}
  
  Fig 2: Identifying Control Valve Body Bolts
  Courtesy of MAZDA MOTORS CORP.
NOTE:
- Aligning the bolt holes, temporarily tighten the bolt by hand.
Temporarily install the suction cover and a new gasket with the bolts.

Fig 3: Identifying Suction Cover And Bolts
Courtesy of MAZDA MOTORS CORP.
Tighten the bolts in the order shown in the figure.

Fig 4: Valve Body Bolt Tighten Sequence
Courtesy of MAZDA MOTORS CORP.

Tightening torque

8-12 N.m {82-122 kgf.cm, 72-105 in.lbf}
Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.

Fig 5: Identifying Input/Turbine Speed Sensor Connector
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- If the control valve body cover is installed with the wiring harnesses overlapped, the wiring harnesses may be pinched between the cover and valve body causing the wiring harnesses to be damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the control valve body cover.
  
  Fig 6: Precaution For Wiring Harness Overlap
  Courtesy of MAZDA MOTORS CORP.
Apply ATF to a new O-ring and install it on the TFT sensor.
Install the TFT sensor with the lock plate and a bolt to the control valve body component as shown in the figure.
Tightening torque

8-12 N.m {82-122 kgf.cm, 72-105 in.lbf}
Connect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.

Fig 7: Identifying TFT Sensor With Lock Plate And Bolt
Courtesy of MAZDA MOTORS CORP.
Connect the coupler component to the clamps.
NOTE:
- Completely remove sealant and oil with white gasoline or similar.
  
  Fig 8: Identifying Coupler Component From Clamp
  Courtesy of MAZDA MOTORS CORP.
Clean sealant and oil off the contact surface of the transaxle case with the control valve body cover and the bolt holes.

Fig 9: Clean Sealant And Oil From Contact Surface Of Transaxle Case
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Completely remove oil with white gasoline or similar.
Clean oil off the contact surface of the new control valve body cover with the transaxle case.
Apply sealant to the new control valve body cover as shown in the figure.
CAUTION:
- Be careful that the coupler component will not become caught between the control valve body cover and transaxle case.
  
  Fig 10: Identifying Sealant Area Of Control Valve Body Cover
  Courtesy of MAZDA MOTORS CORP.
Install the new control valve body cover with new seal bolts.
Tightening torque

9.8-15.7 N.m {100-160 kgf.cm, 87-138 in.lbf}
Install the thermo valve. (See OIL COOLER REMOVAL/INSTALLATION .)
Install the resonance chamber. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION ).

Fig 11: Locating Control Valve Body Cover Installation Bolt
Courtesy of MAZDA MOTORS CORP.
Install the TCM. (See TCM REMOVAL/INSTALLATION .)
Add ATF to the specified level. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .)
Install the under cover.
Install the air cleaner component. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION ).
Connect the negative battery cable.
Perform the mechanical system test. (See MECHANICAL SYSTEM TEST .)