Engine: Removal & Installation Mazda MX-5 NA

Installation

1. To install, reverse removal procedure. After installing engine mount nuts, mount PPF to transmission, and tighten long bolts by hand. Ensure bolt sleeve and PPF/differential mounting spacer are installed to differential housing block.
2. Tighten PPF/differential mounting spacer bolts to 27-38 ft. lbs.(37-52 N.m). (Scheme 3) Install PPF to differential. Hand-tighten longbolts. Ensure PPF-to-differential large shank reamer bolt and spacer are properly installed. NOTE: Reamer bolt is the front long bolt attaching PPF to differential. This bolt aligns PPF with drive train.
3. When PPF is properly aligned between transmission and differential, tighten all long mounting bolts to specification. Install rear transmission-to-PPF bracket, and tighten to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. To complete installation, reverse removal procedure. Before installing M/T shift lever, add gear oil to transmission through shifter hole. Fill all fluids to correct levels.

Scheme 3

Removal

1. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and ducting. see scheme 2 Mark and disconnect coolant hoses, vacuum hoses and electrical connectors from intake manifolds.
2. Disconnect throttle cable. Remove fuel lines from fuel rail and pressure regulator. Remove throttle body intake duct housing and throttle body. Remove air valve.
3. On all models, remove intake manifold support bracket from underneath manifold. Disconnect injector harness connectors, and remove injectors/fuel rail assembly. Remove intake manifold and gasket.

1. Ensure all gasket surfaces are clean and flat. Install NEW gasket and intake manifold to cylinder head. Tighten manifold bolts/nuts evenly to specification, starting from center bolt and alternating outward. See TORQUE SPECIFICATIONS TABLE at the end of this article. Install support bracket underneath intake manifold.
2. Install gasket and upper intake manifold (if equipped). Tighten bolts/nuts evenly to specification, alternating from top to bottom. See TORQUE SPECIFICATIONS TABLE at the end of this article.
3. To complete installation, reverse removal procedure. Ensure Throttle cable has .04-.12" (1-3 mm) free play. Ensure injectors twist freely and are not cocked in insulator "O" rings. Refill engine with coolant.