INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [LF]
![INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [LF]](/img2/20/intake-air.webp)
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata2007 ENGINE PERFORMANCEIntake Air System - MX-5 MiataINTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [LF]Fig. 1: Identifying Intake Air System Hose Routing DiagramCourtesy of MAZDA MOTORS CORP.INTAKE AIR SYSTEM LOCATION INDEX [LF]MicrosoftThursday, July 09, 2009 2:40:222:40:17 PMPage 1 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 2: Identifying Intake Air System ComponentsCourtesy of MAZDA MOTORS CORP.INTAKE AIR SYSTEM DIAGRAM [LF]MicrosoftThursday, July 09, 2009 2:40:18 PMPage 2 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 3: Intake Air System DiagramCourtesy of MAZDA MOTORS CORP.INTAKE MANIFOLD VACUUM INSPECTION [LF]1. Verify that the intake air hoses are installed securely.2. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (purge solenoidvalve side) and install the vacuum gauge.3. Warm up the engine.4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge. If not within the specification, perform the following inspections. Compression pressure (See COMPRESSION INSPECTION [LF] .) Air intake Each hose installation part Throttle body installation part Fuel injector installation part PCV valve installation part Dynamic chamber installation port Intake manifold installation partStandard-60 kPa {-450 mmHg, -17.7 inHg} or moreINTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF]WARNING: A hot engine and intake air system can cause severe burns. Turn offMicrosoftThursday, July 09, 2009 2:40:18 PMPage 3 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata 1.2.3.4.the engine and wait until they are cool before removing the intake-airsystem.Fuel line spills and leakage from the pressurized fuel system aredangerous. Fuel can ignite and cause serious injury or death anddamage. Fuel can also irritate skin and eyes. To prevent this, alwayscomplete the "Fuel Line Safety Procedure", while referring to the"BEFORE SERVICE PRECAUTION [LF] ".Remove the battery cover.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)Remove in the order indicated in the table.Install in the reverse order of removal.Fig. 4: Identifying Removal Order Of Intake-Air System (Step 1) (With Torque Specifications)Courtesy of MAZDA MOTORS CORP.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 4 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 5: Identifying Removal Order Of Intake-Air System (Step 2) (With Torque Specifications)Courtesy of MAZDA MOTORS CORP.AIR CLEANER COVER REMOVAL NOTE1. Remove the MAF/IAT Sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE(IAT) SENSOR REMOVAL/INSTALLATION [LF] .)AIR HOSE REMOVAL NOTE1. Move the purge solenoid valve slightly out of the way. (See PURGE SOLENOID VALVEREMOVAL/INSTALLATION [LF] .)FRESH-AIR DUCT REMOVAL NOTE1. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .)THROTTLE BODY REMOVAL NOTE1. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [LF] .)DYNAMIC CHAMBER REMOVAL NOTEMicrosoftThursday, July 09, 2009 2:40:18 PMPage 5 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuelfrom spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)3. Remove the service hole cover.1. Remove the front suspension tower bar (joint), (right side) and (left side). (See FRONTSUSPENSION TOWER BAR REMOVAL/INSTALLATION .)2. Remove the wiper arm. (See WIPER ARM AND BLADE REMOVAL/INSTALLATION .)3. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)4. Remove the side cowl grille. (See SIDE COWL GRILLE REMOVAL/INSTALLATION .)5. Move the cooler pipe No.3 and heater pipe slightly out of the way.6. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)Fig. 6: Moving Cooler Pipe No.3 & Heater PipeCourtesy of MAZDA MOTORS CORP.4. Disconnect the heater hose and move the heater pipe slightly out of the way.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 6 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 7: Disconnecting Heater HoseCourtesy of MAZDA MOTORS CORP.5. Disconnect the heater hose and move the heater pipe slightly out of the way.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 7 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 8: Moving Heater PipeCourtesy of MAZDA MOTORS CORP.6. Remove the harness bracket.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 8 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 9: Removing Harness BracketCourtesy of MAZDA MOTORS CORP.7. Remove the under cover. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)8. Disconnect the variable intake air solenoid valve connector, EGR valve connector, CMP sensor connectorand PSP switch connector.9. Disconnect the ignition coil connector and fuel injector connector and move the harness slightly out ofthe way.10. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASECONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)11. Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)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 VALVEREMOVAL/INSTALLATION [LF] .)16. Remove the dynamic chamber installation bolts.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 9 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 10: Removing Heater Hose & Heater Pipe From Dynamic ChamberCourtesy of MAZDA MOTORS CORP.17. Remove the EGR pipe.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 10 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 11: Identifying EGR Pipe (With Torque Specifications)Courtesy of MAZDA MOTORS CORP.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 theway.21. Move the clutch release cylinder slightly out of the way. (MT) (See CLUTCH RELEASE CYLINDERREMOVAL/INSTALLATION .)22. Disconnect the evaporative hose with the dynamic chamber raised.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 11 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 12: Disconnecting Evaporative HoseCourtesy of MAZDA MOTORS CORP.23. Remove the dynamic chamber.24. Remove the variable intake air shutter valve actuator. (See VARIABLE INTAKE AIR SHUTTERVALVE ACTUATOR REMOVAL/INSTALLATION [LF] .)25. Remove the MAP sensor. (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORREMOVAL/INSTALLATION [LF] .)THROTTLE BODY INSTALLATION NOTE1. Tighten the bolts in the order as shown in Fig. 13 .Throttle body tightening torque 8.0-11.5 N.m {82-110 kgf.cm, 71-100 in.lbf}MicrosoftThursday, July 09, 2009 2:40:18 PMPage 12 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 13: Identifying Tightening Sequence Of Throttle Body BoltsCourtesy of MAZDA MOTORS CORP.AIR CLEANER ELEMENT INSPECTION [LF]1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)2. Inspect the following items: If there is any abnormality, clean or replace the air cleaner element. Has the replacement interval come? Is the air cleaner element soiled, damaged, or bent? Are the air cleaner case and the air cleaner element correctly sealed? Is the correct air cleaner element installed?THROTTLE BODY INSPECTION [LF]NOTE: Perform the following inspection only when directed.RESISTANCE INSPECTIONMicrosoftThursday, July 09, 2009 2:40:18 PMPage 13 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata1.2.3.4.Remove the battery cover.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)Disconnect the throttle body connector.Measure the resistance between throttle actuator terminals A and B. If not as specified, replace the throttle body. (See INTAKE-AIR SYSTEMREMOVAL/INSTALLATION [LF] .) If as specified, carry out the Circuit Open/Short Inspection .SpecificationAMBIENT TEMPERATURE SPECIFICATIONAmbient temperature ( C { F})Approx. 20 {68}Resistance (ohm)0.3-100Fig. 14: Identifying Throttle Actuator Connector TerminalsCourtesy of MAZDA MOTORS CORP.CIRCUIT OPEN/SHORT INSPECTION1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)2. Inspect the following wiring harnesses for open or short (continuity check).MicrosoftThursday, July 09, 2009 2:40:18 PMPage 14 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 15: Identifying Throttle Valve Actuator & PCM Connector TerminalsCourtesy of MAZDA MOTORS CORP.Open Circuit If there is no continuity, the circuit is open. Repair or replace the wiring harness. Throttle valve actuator terminal A and PCM terminal 2B Throttle valve actuator terminal B and PCM terminal 2AShort CircuitMicrosoftThursday, July 09, 2009 2:40:18 PMPage 15 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata If there is continuity, the circuit is shorted. Repair or replace the wiring harness. Throttle valve actuator terminal A and power supply Throttle valve actuator terminal A and ground Throttle valve actuator terminal B and power supply Throttle valve actuator terminal B and groundVARIABLE INTAKE AIR SOLENOID VALVE REMOVAL/INSTALLATION [LF]1.2.3.4.5.Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)Remove the battery cover.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)Remove in the order indicated in Fig. 16 .Install in the reverse order of removal.Fig. 16: Identifying Removal Order Of Variable Intake Air Solenoid Valve (With TorqueSpecifications)Courtesy of MAZDA MOTORS CORP.VARIABLE INTAKE AIR SOLENOID VALVE INSPECTION [LF]MicrosoftThursday, July 09, 2009 2:40:18 PMPage 16 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataNOTE: Perform the following inspection only when directed.AIRFLOW INSPECTION1. Remove the battery cover2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)3. Remove the variable intake air solenoid valve. (See VARIABLE INTAKE AIR SOLENOID VALVEREMOVAL/INSTALLATION [LF] .)4. Inspect airflow between the ports under the following conditions. If not as specified, replace the variable intake air solenoid valve. If as specified, carry out the Circuit Open/Short Inspection .Fig. 17: Variable Intake Air Solenoid Valve Continuity Check TableCourtesy of MAZDA MOTORS CORP.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 17 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 18: Identifying Variable Intake Air Solenoid Valve PortsCourtesy of MAZDA MOTORS CORP.CIRCUIT OPEN/SHORT INSPECTION1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [LF] .)2. Inspect the following wiring harness for open or short (continuity check).MicrosoftThursday, July 09, 2009 2:40:18 PMPage 18 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 19: Identifying Variable Intake Air Solenoid Valve, Main Relay & PCM Connector TerminalsCourtesy of MAZDA MOTORS CORP.Open Circuit If there is no continuity, the circuit is open. Repair or replace the wiring harness. Variable intake air solenoid valve terminal B and PCM terminal 2J Variable intake air solenoid valve terminal A and main relayShort CircuitMicrosoftThursday, July 09, 2009 2:40:18 PMPage 19 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata If there is continuity, the circuit is shorted. Repair or replace the wiring harness. Variable intake air solenoid valve terminal B and power supply Variable intake air solenoid valve terminal B and body ground Variable intake air solenoid valve terminal A and body groundVARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR INSPECTION [LF]1. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)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 movesusing 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 VARIABLEINTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [LF] .)Fig. 20: Identifying Variable Intake Air Solenoid Valve & Variable Intake Air Shutter ValveActuatorCourtesy of MAZDA MOTORS CORP.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 20 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataVARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR ROD OPERATION REFERENCEVacuum kPa {mmHg, inHg}Rod movementBelow -2.7 {-21, -0.9}Not operateAbove -33.4 {-251, -9.89}Fully pulledVARIABLE INTAKE AIR SHUTTER VALVE ACTUATORREMOVAL/INSTALLATION [LF]WARNING: 1.2.3.4.5.6.7.8.A hot engine and intake-air system can cause severe burns. Turn offthe engine and wait until they are cool before removing the intake-airsystem.Fuel line spills and leakage from the pressurized fuel system aredangerous. Fuel can ignite and cause serious injury or death anddamage. Fuel can also irritate skin and eyes. To prevent this, alwayscomplete the "Fuel Line Safety Procedure", while referring to the"BEFORE SERVICE PRECAUTION [LF] ".Remove the battery cover.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)Remove the throttle body. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)Disconnect the quick release connector (Type A) (See QUICK RELEASE CONNECTOR(EMISSION SYSTEM) REMOVAL/INSTALLATION [LF] .)Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF] .)Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuelfrom spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [LF] .)Remove the service hole cover.1. Remove the front suspension tower bar (joint), (right side) and (left side). (See FRONTSUSPENSION TOWER BAR REMOVAL/INSTALLATION .)2. Remove the wiper arm. (See WIPER ARM AND BLADE REMOVAL/INSTALLATION .)3. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)4. Remove the side cowl grille. (See SIDE COWL GRILLE REMOVAL/INSTALLATION .)5. Remove the service hole cover. (See EGR VALVE REMOVAL/INSTALLATION [LF] .)Remove the harness bracket.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 21 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 21: Identifying Harness BracketCourtesy of MAZDA MOTORS CORP.9. Remove the under cover. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)10. Disconnect the quick release connector from the fuel distributor. (See QUICK RELEASECONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [LF] .)11. Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF] .)12. Move the clutch release cylinder slightly out of the way. (MT) (See CLUTCH RELEASE CYLINDERREMOVAL/INSTALLATION .)13. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] .)14. Remove in the order indicated in Fig. 22 .MicrosoftThursday, July 09, 2009 2:40:18 PMPage 22 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 22: Identifying Removal Order Of Variable Intake Air Shutter Valve Actuator (With TorqueSpecifications)Courtesy of MAZDA MOTORS CORP.15. Install in the reverse order of removal.VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR REMOVAL NOTE1. Disengage the variable intake air shutter valve actuator rod from the dynamic chamber on the oppositeside using a suitable screwdriver or equivalent tool as shown in Fig. 23 .CAUTION: Do not remove the lever, otherwise the variable intake air shuttervalve opening angle will deviate. To prevent removal of the leverwhen removing the variable intake shutter valve actuator, press thelever firmly to the dynamic chamber side by hand.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 23 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 23: Disengaging Variable Intake Air Shutter Valve Actuator Rod From Dynamic ChamberCourtesy of MAZDA MOTORS CORP.VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR INSTALLATION NOTE1. Press the variable intake air shutter valve actuator rod into the dynamic chamber on the opposite side untila click is heard, and install it.ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF]1. Remove the battery cover.2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)3. Remove in the order indicated in Fig. 24 .MicrosoftThursday, July 09, 2009 2:40:18 PMPage 24 2005 Mitchell Repair Information Company, LLC.
2007 Mazda MX-5 Miata Sport2007 ENGINE PERFORMANCE Intake Air System - MX-5 MiataFig. 24: Identifying Removal Order Of Accelerator Pedal (With Torque Specifications)Courtesy of MAZDA MOTORS CORP.4. Install in the reverse order of removal.MicrosoftThursday, July 09, 2009 2:40:18 PMPage 25 2005 Mitchell Repair Information Company, LLC.
Intake Air System - MX-5 Miata INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [LF] Fig. 1: Identifying Intake Air System Hose Routing Diagram Courtesy of MAZDA MOTORS CORP. INTAKE AIR SYSTEM LOCATION INDEX [LF] 2007 Mazda MX-5 Miata Sport 2007 ENGINE PERFORMANCE Intake Air System - MX-5 Miata Microsoft
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Removal steps D Battery 1. Air duct 2. Vacuum hose D AirpipeE,Airby-passvalveassembly, Air by-pass hose (Refer to P.15-9.) 3. Air intake hose 4. Air flow sensor assembly 5. Gasket 6. Air cleaner assembly 7. Air cleaner cover 8. Air cleaner element 9. Air cleaner body 10. Waste gate solenoid valve 11. Air cleaner bracket
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Remove the factory air intake or Cold Air Intake (CAI) - C&L Racer Intake pictured o Disconnect the MAF sensor. (Figure 2) o Disconnect the passenger side PCV hose . o Disconnect air intake from throttle b ody. o Disconnect air filter box (or CAI heat shield) . o Remove air intake.
the factory intake to the new RDP intake. Then install the intake support hand tight. Step 11: Install the RDP Cold Air Intake into the vehicle with the remaining hose clamp. Connect the PCV silicone tube to the intake, and reconnect the MAF sensor. Note: The silicone P
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