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Proj. Cosmo

Nate Bowen

Arturo Chia

Old Updates

• I have not done it for a while so I am doing it from memory.  I would also recommend changing your vacuum lines and considering the TB mod to make things easier next time and if you had it in mind already.
• Needle nose pliers
• 6mm, 8mm, 10mm, 12mm, 14mm sockets and wrench
• Paper towels
• Fire extinguisher!
• Squirter bottle with water in it
• New O-rings and grommets for the injectors recommended.  Go to your Mazda dealer and oversee the parts they order because mine got them wrong.
• 12mm box end wrench
• New upper to lower manifold intake gasket

Procedure:

• CAUTION.  GAS IS FLAMMABLE SO BE VERY CAREFUL AND DO NOT, I REPEAT, DO NOT DO THIS WHEN THE CAR IS HOT.  IF YOU DO, GAS WILL STILL BE UNDER PRESSURE AND WHEN YOU PULL THE INJECTORS OR FUEL LINE IT WILL SPRAY ON YOU.
• Pull off intercooler by removing two vacuum lines and a 10mm bolt on the rear hose and an 8mm bolt on the front hose.
• Now, you will want to remove the throttle cables.  The best way is to remove the plate that holds them to the manifold.  First open the throttle with your hand and pull out the ends of the cables.  The throttle will pull out easily but the cruise (if you have it) will kind of pop out.  Now remove the 2 10mm bolts holding the plate to the intake manifold and move the cables out of the way.
• I would recommend removing the coolant lines to the BAC and unplugging it so you can remove the whole assembly as one piece.  If you plug the lines with a bolt you will not loose much coolant.
• Now you will want to remove the 1 bolt and 4 nuts holding on the upper intake manifold.   They are all 12mm and it is recommended that you replace the intake gasket at this time.  You may have to remove the AWS to get at one of the nuts.  This is the thing that is on top of the upper mani held on by 2 10mm nuts.
• Now go to the drivers side of the throttle body and you will see a 12mm, maybe 14mm, nut holding the TB to the intercooler mounting plate.  Mine didn't have this nut.   Loosen it but do not remove it.
• The whole upper manifold and TB assembly should be loose now, may require a few taps to loosen it.
• Remove all vacuum line attached to the upper manifold but REMEMBER WHERE THEY GO!   There should be 4 on the firewall side on the upper mani and 3 on the radiator side.
• You will also have to loosen the hose from the BAC to the turbo connecting pipe and move it out of the way.  There may be a vacuum line attached near there as well.
• There is also one big vacuum hose connected to a metal pipe on the firewall behind the TB.  You will need to push it down to get it off.
• Unplug the TPS and any other connectors that are attached to the upper mani and TB.
• Now, when you are sure that everything is disconnected you can lift the assembly up and notice that there is a REALLY annoying coolant line to the bottom of the TB.  If you hold the assembly up you can pull the line off but some coolant will spill out so be ready for it.
• OK!  Hopefully you now have the upper mani and TB off all as one piece.  If you do, you have done things right:)
• Now you will see you secondary fuel rail near the lower to upper intake holes.   Those are your secondary injectors.  Your primary injectors are the ones on top of the block right next to each other.
• You should see the fuel lines now.  The way they go is first into the primary rail, then up to the secondary rail, then back to the tank.  First remove the line going up to the secondary rail from the primary rail.  You will push it down and you should be able to get it off.  Gas will begin spilling at this point so have towels ready.   You may have to first remove the secondary rail by removing the 2 12mm nuts holding it down.
• Now remove the return line on the secondary fuel rail and your sendondaries should be free.
• Now remove the 2 12mm nuts from the primary rail and remove the feed line to the rail and your primaries should now be free.  Be careful here because between the rail and the block is a black spacer so don't loose that.
• You have now removed both sets of injectors and all you need to do now is put stuff back together.
• FINAL NOTE:  WHEN PUTTING THE INJECTORS BACK IN, DO NOT TOUCH THEM TO ANYWHERE BECAUSE DIRT CAN GET IN THE TIP AND CAUSE THEM TO STICK OPEN.  NOT FUN!