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Engine - Intake-Air System: Removal & Installation Mazda MX-5 NC

Mechanical 15 illustrations ~920 words

INTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF]

WARNINGA hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system. Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the " BEFORE SERVICE PRECAUTION [LF] ".
  1. Remove the battery cover.
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000) .)
  3. Remove in the order indicated in the table.
  4. Install in the reverse order of removal.

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Air Cleaner Cover Removal Note

  1. Remove the MAF/IAT Sensor. (See «MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [LF]»(ref-244452-S31229317942006092400000) .)

Air Hose Removal Note

  1. Move the purge solenoid valve slightly out of the way. (See «PURGE SOLENOID VALVE REMOVAL/INSTALLATION [LF]»(ref-244459-S15366069222006092400000) .)

Fresh-Air Duct Removal Note

  1. Remove the front bumper. (See «FRONT BUMPER REMOVAL/INSTALLATION»(ref-244484-S25657913212006092400000) .)

Throttle Body Removal Note

  1. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [LF]»(ref-244456-S02885124352006092400000) .)

Scheme 11

Scheme 11: Dynamic Chamber Removal Note
Scheme 11: Dynamic Chamber Removal Note

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-244453-S34821156912006092400000) .)
  2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-244458-S16282158422006092400000) .)
  3. Remove the service hole cover. Remove the front suspension tower bar (joint), (right side) and (left side). (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-244475-S20579544822006092400000) .) Remove the wiper arm. (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-244477-S04548950182006092400000) .) Remove the cowl grille. (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-244478-S13431226702006092400000) .) Remove the side cowl grille. (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-244478-S39487642132006092400000) .) Move the cooler pipe No.3 and heater pipe slightly out of the way. Remove the service hole cover. (See «EGR VALVE REMOVAL/INSTALLATION [LF]»(ref-244459-S41291996702006092400000) .)
  4. Disconnect the heater hose and move the heater pipe slightly out of the way.
  5. Disconnect the heater hose and move the heater pipe slightly out of the way.
  6. Remove the harness bracket.
  7. Remove the under cover. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-244475-S19815374922006092400000) .)
  8. Disconnect the variable intake air solenoid valve connector, EGR valve connector, CMP sensor connector and PSP switch connector.
  9. Disconnect the ignition coil connector and fuel injector connector and move the harness slightly out of the way.
  10. Disconnect the quick release connector from the fuel distributor. (See «QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF]»(ref-244458-S16021009242006092400000) .)
  11. Remove the fuel distributor. (See «FUEL INJECTOR REMOVAL/INSTALLATION [LF]»(ref-244458-S26655812332006092400000) .)
  12. Disconnect the water hose from the EGR valve.
  13. Disconnect two water hoses from the thermostat.
  14. Remove the heater hose and heater pipe from the dynamic chamber.
  15. Remove the variable intake air solenoid valve. (See «VARIABLE INTAKE AIR SOLENOID VALVE REMOVAL/INSTALLATION [LF]»(ref-244455-S18172773442006092400000) .)
  16. Remove the dynamic chamber installation bolts.
  17. Remove the EGR pipe.
  18. Disconnect the connector from the A/C compressor.
  19. Disconnect the knock sensor connector.
  20. Move the vacuum hose between the purge solenoid valve and the charcoal canister slightly out of the way.
  21. Move the clutch release cylinder slightly out of the way. (MT) (See «CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION»(ref-244470-S32817237112006092400000) .)
  22. Disconnect the evaporative hose with the dynamic chamber raised.
  23. Remove the dynamic chamber.
  24. Remove the variable intake air shutter valve actuator. (See «VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]»(ref-244455-S33501838482006092400000) .)
  25. Remove the MAP sensor. (See «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION [LF]»(ref-244452-S31739968622006092400000) .)

Scheme 18

Scheme 18: Throttle Body Installation Note
Scheme 18: Throttle Body Installation Note
  1. Tighten the bolts in the order (Scheme 18) Throttle body tightening torque 8.0-11.5 N.m {82-110 kgf.cm, 71-100 in.lbf}

VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]

WARNINGA hot engine and intake-air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system. Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the " BEFORE SERVICE PRECAUTION [LF] ".

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Remove the battery cover.
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000).)
  3. Remove the throttle body. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-244455-S24513161252006092400000).)
  4. Disconnect the quick release connector (Type A) (See «QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [LF]»(ref-244459-S14287738712006092400000).)
  5. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [LF]»(ref-244453-S34821156912006092400000).)
  6. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See «BEFORE SERVICE PRECAUTION [LF]»(ref-244458-S16282158422006092400000).)
  7. Remove the service hole cover. Remove the front suspension tower bar (joint), (right side) and (left side). (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION»(ref-244475-S20579544822006092400000).) Remove the wiper arm. (See «WIPER ARM AND BLADE REMOVAL/INSTALLATION»(ref-244477-S04548950182006092400000).) Remove the cowl grille. (See «COWL GRILLE REMOVAL/INSTALLATION»(ref-244478-S13431226702006092400000).) Remove the side cowl grille. (See «SIDE COWL GRILLE REMOVAL/INSTALLATION»(ref-244478-S39487642132006092400000).) Remove the service hole cover. (See «EGR VALVE REMOVAL/INSTALLATION [LF]»(ref-244459-S41291996702006092400000).)
  8. Remove the harness bracket.
  9. Remove the under cover. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-244475-S19815374922006092400000).)
  10. Disconnect the quick release connector from the fuel distributor. (See «QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF]»(ref-244458-S16021009242006092400000).)
  11. Remove the fuel distributor. (See «FUEL INJECTOR REMOVAL/INSTALLATION [LF]»(ref-244458-S26655812332006092400000).)
  12. Move the clutch release cylinder slightly out of the way. (MT) (See «CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION»(ref-244470-S32817237112006092400000).)
  13. Remove the dynamic chamber. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF]»(ref-244455-S24513161252006092400000).)
  14. Remove in the order indicated in (Scheme 20).
  15. Install in the reverse order of removal.

Variable Intake Air Shutter Valve Actuator Removal Note

  1. Disengage the variable intake air shutter valve actuator rod from the dynamic chamber on the opposite side using a suitable screwdriver or equivalent tool (Scheme 21)
CAUTIONDo not remove the lever, otherwise the variable intake air shutter valve opening angle will deviate. To prevent removal of the lever when removing the variable intake shutter valve actuator, press the lever firmly to the dynamic chamber side by hand.

Scheme 21

Scheme 21
Scheme 21

Variable Intake Air Shutter Valve Actuator Installation Note

  1. Press the variable intake air shutter valve actuator rod into the dynamic chamber on the opposite side until a click is heard, and install it.

Scheme 22

Scheme 22: VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR INSPECTION [LF]
Scheme 22: VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR INSPECTION [LF]
  1. Remove the service hole cover. (See «EGR VALVE REMOVAL/INSTALLATION [LF]»(ref-244459-S41291996702006092400000) .)
  2. Disconnect the vacuum hose from the variable intake air solenoid valve.
  3. Connect a vacuum pump to the vacuum hose. NOTE: Verify that the variable intake air shutter valve actuator rod moves using a mirror.
  4. Apply vacuum and verify that the rod moves. If the rod does not move, replace the variable intake air shutter valve actuator. (See «VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF]»(ref-244455-S33501838482006092400000) .)
Vacuum kPa {mmHg, inHg}Rod movement
Below -2.7 {-21, -0.9}Not operate
Above -33.4 {-251, -9.89}Fully pulled

VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR ROD OPERATION REFERENCE

Scheme 23

Scheme 23: ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF]
Scheme 23: ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF]
  1. Remove the battery cover.
  2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [LF]»(ref-244448-S25513985422006092400000).)
  3. Remove in the order indicated in (Scheme 23).
  4. Install in the reverse order of removal.

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