Miata 1990-1997

Intake Manifold

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Removal & Installation



Specific to:

Mazda Miata 1990-1994



Click image to see an enlarged view

Fig. The air intake assembly


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Properly relieve the fuel system pressure. Disconnect the negative battery cable and drain the cooling system.
  2.  
  3. Disconnect the air intake hose from the throttle body. Remove the hose and air cleaner assembly if necessary.
  4.  
  5. Disconnect the accelerator cable. Disconnect and plug the fuel lines.
  6.  
  7. Label and disconnect all necessary vacuum hoses and electrical connectors. Disconnect the coolant hoses.
  8.  
  9. Disconnect the EGR tube, if equipped.
  10.  
  11. If equipped, remove the air valve and remove the fuel rail attaching bolts. Remove the fuel rail and injectors as an assembly.
  12.  
  13. Remove the intake manifold support bracket. If necessary, remove the bolt retaining the dipstick tube bracket to the intake manifold.
  14.  
  15. Remove the intake manifold-to-cylinder bolts/nuts and remove the intake manifold assembly.
  16.  
  17. If necessary, remove the throttle body and separate the intake manifold upper and lower halves.
  18.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. If separated, connect the upper and lower intake manifolds using a new gasket. Tighten the nuts/bolts to 19 ft. lbs. (25 Nm). If removed, install the throttle body using a new gasket. Tighten the retaining nuts/bolts to 19 ft. lbs. (25 Nm).
  4.  
  5. Install the intake manifold assembly to the cylinder head using a new gasket. Tighten the nuts/bolts to 19 ft. lbs. (25 Nm).
    NOTE
    Tighten the bolts in the center of the manifold first and works outward toward the ends.

  6.  
  7. If equipped, install the bolt retaining the dipstick tube to the intake manifold. Install the intake manifold bracket. Tighten the attaching nuts/bolts to 38 ft. lbs. (52 Nm).
  8.  
  9. Install the fuel rail and injector assembly on the intake manifold using new insulators. Tighten the fuel rail mounting bolts to 19 ft. lbs. (25 Nm). Install the air valve and tighten the bolts to 57 inch lbs. (6 Nm).
  10.  
  11. Connect the EGR tube, if equipped. Connect the coolant and vacuum hoses, electrical connectors and fuel lines.
  12.  
  13. Connect the accelerator cable. Install the air cleaner assembly, if removed, and connect the air intake tube to the throttle body.
  14.  
  15. Connect the negative battery cable. Fill and bleed the cooling system.
  16.  
  17. Start the engine and bring to normal operating temperature. Check for leaks. Check the idle speed.
  18.  

Specific to:

Mazda Miata 1995-1997



Click image to see an enlarged view

Fig. The air intake assembly

  1. Relieve the fuel system pressure, and disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Disconnect the mass air flow sensor electrical connector. Remove the air ducts, air cleaner assembly, mass air flow sensor and resonance chamber.
  4.  
  5. Disconnect the throttle and accelerator cables. Disconnect and plug the fuel lines.
  6.  
  7. Remove the throttle body as follows:
    1. Disconnect the coolant hoses.
    2.  
    3. Label and disconnect the electrical connectors for the idle air control valve and the throttle position sensor.
    4.  
    5. Remove the mounting bolts/nuts from the throttle body, and remove the throttle body from the vehicle.
    6.  

  8.  
  9. Label and disconnect the vacuum lines at the intake manifold.
  10.  
  11. Remove the dynamic chamber (upper intake manifold).
  12.  
  13. Disconnect and plug the fuel hoses from the fuel rail.
  14.  
  15. Label and disconnect the electrical connectors for the fuel injectors.
  16.  
  17. On some models you may need to remove the fuel rail with the injectors connected.
  18.  
  19. Remove the intake manifold support bracket.
  20.  
  21. Remove the bolts and nuts, and remove the intake manifold.
  22.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install the intake manifold, using a new gasket. Tighten the nuts and bolts to 14-18 ft. lbs. (19-25 Nm).
  4.  
  5. Attach the EGR pipe to the manifold and install the intake manifold support bracket. Tighten the support bracket bolts to 38 ft. lbs. (51 Nm).
  6.  
  7. If removed, install the EGR and pressure regulator control (PRC) solenoid valve brackets.
  8.  
  9. Install the fuel rail and injector assembly. Connect the electrical connectors to the injectors,and the fuel lines to the rail.
  10.  
  11. Install the upper intake manifold to the intake manifold using new gaskets. Tighten the nuts to 14-18 ft. lbs. (19-25 Nm).
  12.  
  13. Install the throttle body, using a new mounting gasket. Tighten the mounting bolts to 14-18 ft. lbs. (19-25 Nm).
  14.  
  15. Connect the electrical connectors for the idle air control valve and the throttle position sensor.
  16.  
  17. Connect the vacuum and coolant lines.
  18.  
  19. Connect and adjust the throttle and accelerator cables.
  20.  
  21. Connect the fuel lines.
  22.  
  23. Install the resonance chamber. Install the air cleaner assembly, mass air flow sensor and ducts. Connect the mass air flow sensor connector.
  24.  
  25. Connect the negative battery cable. Fill and bleed the cooling system. Run the engine and check for leaks.
  26.  

 
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