KLZE Intake Manifold (IM) install onto KL03/DE engines (Omaha95PGT):
Parts needed:
-KLZE Intake manifold
-KL03 IM Phenolic spacer or KLZE IM gasket (aka Mazda Millenia 2.5L IM gasket)
-2 vacuum "T's" (if you need HVAC controls and cruise control vacuum) [5/32" fittings seem to work the best]
-zip ties
-5/16" ID heater/fuel hose about 2 feet worth (for the IAC coolant ports)
-9/16" heater hose ~3 feet worth (for the rear VC vent to the TB elbow)
-TB/IAC combinations: ZE TB/ZE IAC, modified 03 TB/ZE IAC, or 03 TB/03 IAC "T" and vac hose See directions several posts below
-Permatex Seal-a-Gasket #2 non-hardening gasket sealant
-new vac hose (if needed) 5/32" ID rubber or silicone hose
-screw type hose clamps (a lot of them various sizes small-->medium)
-2 new copper crush washers for the fuel rail banjo bolt (replacement is recommended)
Tools needed:
-7, 8, 10, 12, 17 mm socket (also 13 mm socket if you used the Outlaw Phenolic extended fasteners)
-Phillips screwdriver
-socket extensions various
-1/4", 3/8" ratchet
-Dremel/Rotary tool with grinding bit and barrel sander 1/4"
-box cutter razor blade with handle
-torque wrenches
-Pliers (various-needle nose, standard, etc)
-masking tape and marker
-vacuum cleaner
-compressed air with trigger nozzle or canned air
Torque specs:
-intake manifold nuts/bolts 14-18 ft-lb
-throttle body nuts 15-22 ft-lb
-throttle body bolts 14-18 ft-lb
Procedure:
-use the vacuum cleaner with crevice extension and the compressed or canned air to clean all of the grit and sand that's sitting in the area where the IM and the heads meet. Consider spraying some WD40 down there to hold still the grit you couldn't blow or vacuum out before lifting the IM off. Once the IM is off you can wipe up the remaining grit. Stuff paper towel or rags into the head intake ports to prevent debris from entering the cylinders. Optionally, you can tape the intake ports shut with some masking tape.
http://forums.probetalk.com/showthre...did=1700975049
There are only a few differences with the 03 intake manifold (IM) removal and the fitment of a ZE IM. I'll go thru some of the common problems below.
edit - fixed the link
Parts needed:
-KLZE Intake manifold
-KL03 IM Phenolic spacer or KLZE IM gasket (aka Mazda Millenia 2.5L IM gasket)
-2 vacuum "T's" (if you need HVAC controls and cruise control vacuum) [5/32" fittings seem to work the best]
-zip ties
-5/16" ID heater/fuel hose about 2 feet worth (for the IAC coolant ports)
-9/16" heater hose ~3 feet worth (for the rear VC vent to the TB elbow)
-TB/IAC combinations: ZE TB/ZE IAC, modified 03 TB/ZE IAC, or 03 TB/03 IAC "T" and vac hose See directions several posts below
-Permatex Seal-a-Gasket #2 non-hardening gasket sealant
-new vac hose (if needed) 5/32" ID rubber or silicone hose
-screw type hose clamps (a lot of them various sizes small-->medium)
-2 new copper crush washers for the fuel rail banjo bolt (replacement is recommended)
Tools needed:
-7, 8, 10, 12, 17 mm socket (also 13 mm socket if you used the Outlaw Phenolic extended fasteners)
-Phillips screwdriver
-socket extensions various
-1/4", 3/8" ratchet
-Dremel/Rotary tool with grinding bit and barrel sander 1/4"
-box cutter razor blade with handle
-torque wrenches
-Pliers (various-needle nose, standard, etc)
-masking tape and marker
-vacuum cleaner
-compressed air with trigger nozzle or canned air
Torque specs:
-intake manifold nuts/bolts 14-18 ft-lb
-throttle body nuts 15-22 ft-lb
-throttle body bolts 14-18 ft-lb
Procedure:
-use the vacuum cleaner with crevice extension and the compressed or canned air to clean all of the grit and sand that's sitting in the area where the IM and the heads meet. Consider spraying some WD40 down there to hold still the grit you couldn't blow or vacuum out before lifting the IM off. Once the IM is off you can wipe up the remaining grit. Stuff paper towel or rags into the head intake ports to prevent debris from entering the cylinders. Optionally, you can tape the intake ports shut with some masking tape.
http://forums.probetalk.com/showthre...did=1700975049
There are only a few differences with the 03 intake manifold (IM) removal and the fitment of a ZE IM. I'll go thru some of the common problems below.
edit - fixed the link
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