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Engine Controls - Remove/install/overhaul: Removal & Installation Mazda MX-5 NA

Removal & Installation 7 illustrations ~2080 words

Removal & Installation (Miata)

Disconnect sensor connector. Remove hold-down bolt. Remove sensor. To install, reverse removal procedure. Adjust ignition timing. See ADJUSTMENTS article. Tighten bolt to specification. See the TORQUE SPECIFICATIONS table.

Removal & Installation (MX-3 1.8L, MX-6 2.5L & 626 2.5L)

Crank angle sensor is located on front of engine near crank pulley. To remove, disconnect negative battery cable. Remove idle pulley bracket. Remove dipstick pipe. Disconnect sensor connector. Remove sensor. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Adjust ignition timing. See ADJUSTMENTS article.

Removal & Installation (RX7)

Disconnect negative battery cable. Remove drive belt. Remove crankshaft pulley and crank angle sensor plate. Remove nuts and sensor bracket. Disconnect electrical connectors. Remove crank angle sensors. To install, reverse removal procedure. Tighten sensor mounting nuts to specification. See TORQUE SPECIFICATIONS table.

Removal & Installation (929)

Crank angle sensor is located on front of engine, near crank pulley. To remove, disconnect sensor connector. Remove mounting bolt. Remove sensor. To install, reverse removal procedure. Adjust ignition timing. See ADJUSTMENTS article. Tighten bolt to specification. See TORQUE SPECIFICATIONS table.

Removal & Installation (Navajo)

Disconnect negative battery cable. Disconnect crankshaft position sensor connector. (Scheme 2) Remove crankshaft timing sensor mounting screws, and remove sensor. To install, reverse removal procedure. Tighten screws to specification. See TORQUE SPECIFICATIONS table.

Scheme 2

Scheme 2: Removal & Installation (Navajo)
Scheme 2: Removal & Installation (Navajo)

Removal & Installation

Disconnect negative battery cable. Remove air cleaner. Disconnect accelerator cable, cruise control cable (if equipped), all necessary vacuum hoses, fuel hoses and electrical connectors. Remove carburetor mounting nuts. Remove carburetor. To install, reverse removal procedure.

Removal (B2200 Carbureted With Electric Pump, B2200 PFI & B2600i)

Release fuel system pressure (except B2200 Carbureted). See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (B2200 Carbureted With Electric Pump, B2200 PFI & B2600i)

Install new pump in sending unit assembly. Ensure fuel pump wire terminals do not touch hose clamps or bracket assembly. To complete installation, reverse removal procedure.

Removal (Miata, Protege, RX7 & 323)

  1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) .
  2. On Miata, remove rear package trim (behind seat). On Protege and 323, remove rear seat. On RX7, remove carpet in luggage compartment.
  3. On all models, remove fuel pump access cover. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (Miata, Protege, RX7 & 323)

  1. Install fuel pump to assembly using NEW "O" ring, cap and spacer between fuel pump and outlet pipe (coat components with oil or gasoline before installing). (Scheme 3) After installing fuel pump to assembly, blow through outlet pipe (at top of assembly) toward pump to confirm sealing of "O" ring.
  2. If air flows through pump, shake pump several times to dislodge check ball. To complete installation, reverse removal procedure.

Scheme 3

Scheme 3
Scheme 3

Removal (MPV & MX-3)

  1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . Remove rear seat. On MPV, lift rear floor mat.
  2. On all models, remove fuel pump cover. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (MPV & MX-3)

  1. Replace fuel hose between pump and outlet pipe ( DO NOT apply excessive force when installing onto pump nipple). Install hose clamps.
  2. Install pump with wire terminals positioned to avoid contact with metal parts. To complete installation, reverse removal procedure.

Removal (MX-6 & 626)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Turn lock ring counterclockwise. Remove lock ring. Remove fuel pump and sending unit assembly.

Installation (MX-6 & 626)

Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise until tight. Install fuel tank.

  1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) .
  2. Remove rear seat mounting bolts, located between seat bottom and seat back cushions. Remove seat cushions. Remove amplifier and CD changer (if equipped) and lift luggage compartment carpeting. Remove hole cover.
  3. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly. To install, reverse removal procedure.

Removal (Navajo)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Using Fuel Tank Lock Ring Wrench (T86T-9275-A), turn lock ring counterclockwise. Remove lock ring. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation (Navajo)

Clean seal area on tank and assembly flange. Lightly coat NEW "O" ring with molybdenum grease. Install seal in groove. Carefully install assembly into fuel tank, ensuring filter is not damaged and seal remains in groove. Install and turn lock ring clockwise until tight using Fuel Tank Lock Ring Wrench (T86T-9275-A). Install fuel tank.

Removal & Installation (Except Navajo)

  1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . On 929, remove dynamic chamber. On all models, disconnect vacuum and fuel hose(s) from regulator. Remove regulator mounting bolts. Remove regulator, gasket and "O" ring (if equipped).
  2. To install, reverse removal procedure. Install NEW gasket and "O" ring (if equipped). On 929, install dynamic chamber with NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table.
  1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . Disconnect vacuum hose from regulator. Disconnect fuel line coupling at regulator. See «FUEL LINE CONNECTORS (NAVAJO)»(ref-18285-S22969168242000123000000) .
  2. Remove regulator mounting screws. Remove regulator, "O" ring and washer. To install, reverse removal procedure using NEW washer and "O" ring. Lubricate NEW "O" ring with light oil. DO NOT use silicone grease.

Removal & Installation (B2200 PFI, B2600i & MPV 2.6L)

  1. Release fuel system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) under FUEL SYSTEM. Remove throttle body. Refer to «THROTTLE BODY»(ref-18285-S30904684512000123000000) under FUEL SYSTEM.
  2. Remove support brackets and injector harness bracket from dynamic chamber. Disconnect vacuum hoses, PCV hose, intake air thermosensor connector and ground wire from dynamic chamber. Remove dynamic chamber.
  3. Disconnect vacuum hose and fuel hoses from fuel rail. Disconnect injector electrical connectors. Pull fuel rail with injectors and pressure regulator upward to remove. Remove insulators, injectors and "O" rings from fuel rail.
  4. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings, and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting bolts to specification. See TORQUE SPECIFICATIONS table. Install dynamic chamber with NEW gasket.
  1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . Disconnect negative battery cable. Remove air valve and PCV valve hose from intake manifold. Disconnect vacuum and fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove insulators, injectors and "O" rings from fuel rail.
  2. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table.

Removal & Installation (MPV 3.0L)

  1. Release fuel system hydraulic pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) under FUEL SYSTEM in this article. Remove the air intake tube. (Scheme 4) Remove the throttle body. Refer to «THROTTLE BODY»(ref-18285-S30904684512000123000000).
  2. Remove intake air pipe, extension manifolds and upper intake manifold. Disconnect fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove fuel rail and injectors as an assembly. Remove insulators, injectors and "O" rings from fuel rail.
  3. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings, and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting nuts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table. Install NEW extension manifold and intake air pipe gaskets.

Scheme 4

Scheme 4
Scheme 4

Removal & Installation (MX-3 1.6L, MX-6 & 626 2.0L, Protege & 323)

  1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . Disconnect injector electrical connectors. Remove injector harness from fuel rail. Remove fuel rail mounting bolts. Remove fuel rail, injectors and pressure regulator as an assembly.
  2. Remove insulators, injectors and "O" rings from fuel rail. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table.

Removal & Installation (MX-3 1.8L, MX-6 & 626 2.5L)

  1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . Disconnect negative battery cable. Remove air intake tube. Disconnect vacuum and fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove fuel rail, injectors and pressure regulator as an assembly. Remove insulators, injectors and "O" rings from fuel rail.
  2. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table.
  1. Thoroughly clean engine. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000). Disconnect negative battery cable. Remove upper intake manifold and throttle body as an assembly.
  2. Disconnect fuel supply line from fuel supply manifold. See «FUEL LINE CONNECTORS (NAVAJO)»(ref-18285-S22969168242000123000000). Disconnect fuel return line from fuel pressure regulator. Remove fuel supply manifold. (Scheme 5) Disconnect injector electrical connectors and retaining clips. Remove injectors from fuel supply manifold.
  1. Lubricate NEW injector "O" rings with light oil. DO NOT use silicone grease. Carefully install injectors into fuel supply manifold. Carefully install fuel supply manifold into lower manifold using NEW manifold gasket.
  2. Clean and oil fuel supply manifold bolt threads. Install fuel supply manifold bolts. Tighten bolts to specification. See the «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table. To complete installation, reverse removal procedure.

Scheme 5

Scheme 5
Scheme 5
  1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000). Remove air intake duct. (Scheme 6) Remove throttle body. See «THROTTLE BODY»(ref-18285-S30904684512000123000000).
  2. Remove upper intake manifold. Disconnect fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove idle speed control solenoid. Remove fuel rail and injectors as an assembly. Remove insulators, injectors and "O" rings from fuel rail.
  3. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings, and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting nuts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table. Install NEW manifold gaskets.

Scheme 6

Scheme 6
Scheme 6
  1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-18285-S39855759662000123000000) . Remove dynamic chamber and throttle body as an assembly. Disconnect injector electrical connectors. Disconnect vacuum and fuel hoses. Remove fuel rail, injectors and pressure regulator as an assembly.
  2. Remove insulators, injectors and "O" rings from fuel rail. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings, and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table.

Removal

Disconnect oxygen sensor electrical connector. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). If sensor is difficult to remove, use rust penetrant to avoid damaging threads. Carefully remove sensor.

Installation

Apply anti-seize to sensor threads (if reusing old sensor or if new sensor is not coated with anti-seize). Install sensor and tighten to specification. See TORQUE SPECIFICATIONS table. Reconnect sensor electrical connector.

  1. On MPV 3.0L, drain about 2 qts. (1.9 L) of coolant from cooling system. On all models, disconnect negative battery cable. Remove air intake tubes.
  2. Disconnect accelerator cable, coolant hoses and electrical connectors from throttle body as necessary. On 929, remove by-pass air control valve. On all models, remove throttle body. To install, reverse removal procedure using NEW throttle body gasket. See the «TORQUE SPECIFICATIONS»(ref-18285-S38527566862000123000000) table.
  1. Disconnect throttle position sensor electrical connector. Remove snow/ice shield to expose throttle linkage. Remove throttle cable bracket.
  2. Disconnect cable from ball stud on throttle body. Remove air cleaner-to-throttle body air inlet tube. Disconnect canister purge hose from fitting beneath throttle body.
  3. Remove 4 throttle body bolts. Remove throttle body from upper intake manifold.

Install NEW throttle body gasket. To complete installation, reverse removal procedure.

Removal (RX7)

  1. Raise and support vehicle. Drain coolant. Disconnect negative battery cable. Remove air cleaner, intake air hoses and pressure chamber. (Scheme 6) Remove air control valve assembly. Disconnect vacuum hoses.
  2. Remove drive belt and air injection pump. Disconnect oxygen sensor, exhaust downpipe and catalytic converter. Disconnect turbo control valve rod and actuator. (Scheme 7) Disconnect oil pipes from turbocharger. Remove coolant hoses.
  3. Remove bolts securing turbocharger to exhaust manifold. Remove turbocharger assembly.

Installation (RX7)

Install turbocharger with NEW gaskets, "O" rings and exhaust manifold studs. Tighten nuts and bolts to specification. (Scheme 8) See TORQUE SPECIFICATIONS table. To complete installation, reverse removal procedure. Prime oil system.

Scheme 7

Scheme 7: Installation (RX7)
Scheme 7: Installation (RX7)

Scheme 8

Scheme 8
Scheme 8

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