1997 MAZDA MIATA MX 5 Cold Air Induction Kit #901

1997 MAZDA MIATA MX 5 Cold Air Induction Kit #901
Performance Parts
1994 - 1997 MAZDA MIATA MX 5
Cold Air Induction™ Kit
Cold
Air Induction Kit #901-980
1.6 Installation Instructions
901-985
Thank you for choosing Jackson Racing for your Miata performance parts. You will find the Jackson
Racing Cold Air Induction™ Kit easy to install. Stock components removed should be placed in
boxes or plastic bags and marked for easy identification. Access to a Mazda service manual is
always helpful when working on your Miata. (Miata Enthusiast Manual, #211-505.)
This system was designed for use only on the Mazda Miata MX-5. The engine should be in good
running condition prior to installation. It is a good time to install new spark plugs (#971-050) and
check the timing. Set ignition timing to 14 degrees BTDC. NOTE: This should be done before the
C.A.I. is installed as the Air box blocks visual access to the timing marks. Refer to a Mazda
service manual for specific instructions on setting ignition timing.
The air filter provided is washable and reusable. Use a maintenance kit for foam air filters (#901970). Do not use a K&N cleaning kit as it is designed for cotton filters only.
*Please read these instructions completely before installation. You should be able to install the Cold
Air Induction Kit using normal tools. You will need a small amount of antifreeze on hand as you will
see in the instructions.
If there are any questions, please call our staff at 1-800-642-8295
Distributed by:
Moss Motors, Ltd.
440 Rutherford St.
Goleta, CA 93117
Revised 01/03
rev. 1-7-98
Remember before you start...
IfRemember
you want to change
beforeyour
youignition
start...timing, now is the time to do it. Set the ignition timing to 14
degrees BTDC, but remember, if you do this, your car will not pass a smog test in California. it is not
If you want to
ignitiontiming,
timing,only
now isrecommended.
the time to do it.
Set the ignition
timing
to 14 degrees
but
necessary
tochange
reset your
the ignition
Because
of all the
information
fromBTDC,
Miata
remember, ifand
youthe
do this
your car
will not ignition
pass a smog
test settings,
in California.
It is notwe
necessary
reset theyou
ignition
Magazine
Internet
regarding
timing
we thought
shouldto
forewarn
timing,
Miata
Magazine
the Internet
regarding
that
the only
cold recommended.
air induction Because
box will of
getall
in the
the information
way of your from
timing
marks.
Keepand
in mind,
that once
you
ignition
timing
settings,
we
thought
we
should
forewarn
you
that
the
cold
air
induction
box
will
get
in
the
way of
have set the timing, it will not need to be adjusted ever again. It is fully electronic and does not need
your
Keep in
mind, that
onceMiata's
you have
set thefires
timing,
it will not
need every
to be adjusted
ever again. It
to
betiming
reset.marks.
Also, very
important,
your
ignition
an electrical
spark
engine revoluis
fully
electronic
and
does
not
need
to
be
reset.
Also,
your
Miata’s
ignition
fires
an
electrical
spark
every
revolution
tion instead of every other revolution like most other 4 cylinder engines. To properly set the ignition
instead of
every
like most
otherlight.
4 cycle
engines.
To properly
set theto
ignition
timing youtiming
will need a
timing,
you
willother
needrevolution
a high-quality
timing
If you
do not
have access
a high-quality
high quality
timing
light.
If you doreading.
not have Poor
accessquality
to a high
quality
timing
light, youtheir
will get
an improper
reading.
light,
you will
get an
improper
lights
cannot
recharge
bulbs
fast enough
to
Poor
quality
lights
cannot
recharge
their
bulbs
fast
enough
to
send
a
proper
signal.
The
result
is,
your
ignition
send a proper signal. The result is, your ignition timing will actually be retarded from where you think
timing
you
setwill
it. actually be retarded from where you think you set it.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disconnect the negative side of the battery (-) Please note radio security code before disconnecting.
Remove the 4 screws securing the plastic cover in front of the radiator support frame. This will not be
reinstalled.
Loosen hose clamps at each end of stock air intake tube which runs across the top of the radiator.
Remove the crankcase ventilation and idle bypass hoses from the base of the throttle body and the intake
tube. Remove the intake assembly.
Disconnect the two wiring harnesses from the throttle body and set harnesses back out of harms way.
Remove 8 mm bolt (12mm hex) from the bracket which holds the power steering hose support bracket.
(See Fig.1)
Loosen the power steering hose nut just enough to allow the hose to be rotated about 30 degrees
counter clockwise. Re tighten and clean up any leaked power steering fluid.
To allow clearance for the new C.A.I.™ airbox, the power steering hose support bracket will need to be
bent up slightly to prevent contact with the airbox. (See Fig.1) The support bracket will not be re connected. Rotate the bracket which is still attached to the power steering hose back out of the way.
Loosen the hose clamp on the intake tube at the rear of the stock airbox. Remove the 10mm headed bolt
on the drivers side inner fender, and remove the tube.
10. Disconnect wiring harness from air mass sensor and set back out of harm’s way.
11. Remove (2), 6 mm (10mm hex) bolts locating air mass sensor to the air filter box (save these for use
later). Carefully remove air mass sensor.
12. Remove (2), 8 mm (12mm hex) retaining bolts and (1) 8 mm nut and remove the stock airbox. If your
car is equipped with cruise control you will want to remove the cruise control servo assembly first. After
removing the stock airbox, remove the spacer sleeve, the one that was held down by the 8 mm nut, from
the stock air box and install it onto the stud it was removed from, and reinstall the cruise control servo
assembly. Reinstall the 8 mm nut.
13. Depending on the country of origin, some 95 and later cars do not have the air bag sensor mounted to
the front of the car near the hood latch. Disregard this instruction if you have a 95 and later U.S. car.
Locate the air bag sensor (See Fig.2). It is in front of the radiator and to the side of the hood latch. The
air bag sensor harness will be rerouted below the radiator cowl instead of above the cowl. Remove the
plastic air bag sensor cover. (This will not be reused). Unbolt the air bag sensor. Follow air bag sensor
wiring harness to the drivers side of the engine bay, and unplug the air bag sensor plugs. They are
identified by the orange and blue coloring on the plugs. Route the harness under the radiator frame to
the right of the headlight motor knob (Looking from the front of the car) Reconnect to the original plugs
on the drivers side of the engine bay. Important! The harness must not interfere with the headlight
opening and closing. Reinstall Air bag sensor using stock bolts.
It now time to install the new Jackson Racing Cold Air Induction™ System. The new airbox and airflow
meter adapter have been supplied already sealed and assembled.
14. Remove the two 6 mm bolts (10mm hex) at the front of the cowling. These will be replaced with 2-27mm
x 6mm (10mm hex) flanged bolts to locate the air box. See Fig.2.
15. For Miatas equipped with anti-lock brakes, you will need to move the filler neck for the windshield wiper
fluid. The top sticks through a frame hole to the drivers side of the radiator support. You will need to
loosen the support bracket nut and slide the filler tube to the furthest position away from the bracket
bolt. Now, tighten the bracket nut. This will make room for the new air box and provide access to the
washer bottle
16. The air filter, airbox and air mass sensor adapter may now be installed. Standing at the front of the
vehicle, carefully arc the assembly down to the left and under the thermostat housing between the
radiator frame and the front of the engine. A special note about installing the air box and aluminum
adapter. To accommodate the 1.8 liter engine (which is longer than the 1.6), we had to narrow up the
air box and deepen it to achieve the high flow we require for outstanding performance. You will notice
that the airbox is much narrower than the aluminum air mass sensor adapter. The stock Miata air mass
sensor is actually bigger in outside diameter than the area between the cooling fans and the engine.
Consequently, when you are installing the air box and aluminum adapter, you must give the air box a
good push to get it past the cooling fans and the engine. If you remove the aluminum adapter from the
airbox and install it after the air box is in place, you will not have this problem. However, most people
working at home, do not have small universal sockets for reaching down to the bottom of our air box to
reinstall the aluminum adapter mounting bolts. So, even though it looks like it will not fit... it will, just
give the airbox assembly a good push. It will fit just fine once it gets past the cooling fans and thermostat
housing. Install using the 2-27mm x 6mm flanged bolts (10mm hex) and the 2 rubber/metal washers
supplied, between the air box and the flanged bolts, rubber side to airbox. Install the air filter with the
Jackson Racing logo facing up. Install the airbox lid.
17. Apply a small amount of lubricant to the rubber bellows on the air mass sensor and rotate the unit into
the alloy air mass sensor adapter. Install the steel 85BK9005air mass sensor bracket onto the alloy air
mass sensor adaptor using the 2 provided countersunk phillips head screws. install 1 of the original 6mm
air mass sensor bolts through the bracket and into the air mass sensor. Leave the last bolt hole at the left
hand end of air mass sensor empty at this stage. The remaining stock bolt will be used later to attach a
cable tie loop to secure the small coolant bypass hose. (See illustration Fig.3 & 4)
18. Attach the airbox support bracket #85BK9004 to the right rear corner of the airbox using the third
rubber washer between the bracket and air box. Mount to the chassis at the forward stock airbox
locating point using the supplied 8 mm bolt (12mm hex).
19. Attach the flex hose to the bottom end of the cast
aluminum elbow tube and fit to the air mass sensor
rotomolded
using the two 3" hose clamps provided. Make sure the flex hose is compressed as much as possible when
installed (See illustration Fig.3). This will allow the engine to move during acceleration and deceleration.
20. Fit the other end of the cast elbow tube to the throttle body using the short rubber connecting hose
supplied. Secure with the (2) 3" hose clamps provided.
21. Cut the stock idle bypass hose to form a right angle. Fit one end of the hose to the cast elbow fitting and
the other end to the stock outlet at the base of the throttle body. Secure both ends with the stock clamps.
22. Fit crank case ventilation tube to the brass barb fitting on the top of the cast aluminum elbow tube.
23. Re connect the two wiring harnesses to the throttle body. Make sure they snap into place correctly.
24. Now use the rubber insulated clamp supplied, to secure the small coolant bypass hose to the air mass
sensor using the remaining stock 6 mm bolt (10mm hex). Make sure the hose is secured away from the
water pump pulley (See illustration Fig.4).
Wiring harness modification
25. Because we have moved the position of the air mass sensor, it is necessary to add an extension to the air
mass sensor wiring harness.
First, measure back 5 inches from the stock air mass sensor plug. Carefully cut through the harness
protective sheathing to expose the wires. Cut the wires at that point and strip all of the ends back 1/4"
(Note: make sure that all of the gray shielding on the red wire is stripped back and does not make
contact anywhere within the butt connector. This gray shielding does not exist on all models). Slip the
two 4" lengths of shrink tubing (supplied) onto the wiring harness, these will be heat shrunk over the butt
connections when all joints are completed AFTER you have made sure the car runs correctly. Connect the
new harness extension using the butt connectors provided. The new extension wire colors correspond
with the factory harness (See illustration Fig.5). Slip the stock wires into the butt connectors with the
corresponding colors on the extension harness and crimp securely. Apply heat to newly crimped connectors using a Heat gun or Hair drier. This will seal the plastic coating around the butt connector.
26. Route the new harness to the air mass sensor and plug in securely.
27. Tie wrap the harness out of harms way along the crank case ventilation pipe in front of the cam cover
using the wire ties supplied.
28. Check that all fittings and hose clamps are secure. WARNING! Ensure the flex hose between air mass
sensor and cast aluminum elbow has adequate crush when in the installed position. If this is not installed
correctly, damage to your C.A.I.™ Airbox system can result.
29. Relocate the hood rod using the swivel/bracket #9003 and the rod holder supplied. Locate as illustrated.
If your car is equipped with cruise control, it will be necessary to remove the cruise control cable mounting
clip that uses the square slot and tie wrap the cruise control cable to the throttle cable.
30. Reconnect the negative terminal to the battery.
31. Start your engine!
Attach Hood Rod Bracket
& Holder with 6x20mm
(10mm hex) Bolt & Washer
(Right side in front of rubber hood stop)
1994 - 1997 MAZDA MIATA MX 5
Cold Air Induction Kit #901-980
PART #
DESCRIPTION
901-978
CAI HARDWARE 1.8 MIATA
051-005
BOLT,HEX FLANGE,M6 X 1.00 X 25
051-009
BRACKET, HOOD
051-010
BRACKET REAR BOX
051-011
BRACKET, AIR MASS SENSOR
051-016
CABLE TIE
051-017
CLAMP, HOSE, SAE NO. 40
051-030
P-CLAMP, LOOM, 1/2IN. ID
051-032
HOSE, FLEX, 2.75 X 6
051-033
HOSE, SILICONE, 2.635 X 2
051-041
HOLDER, ROD
051-042
HOLDER, ROD
051-044
SCREW, MACHINE, M6 X 1.0 X 12
051-045
SHRINK TUBE, 3/4ID X 5 IN.
051-127
BOLT FLANGED 8X20X1.25
051-190
CLAMP,HOSE,#6
051-051
WASHER
051-000
ADAPTER, METER
051-004
BOLT,HEX FLANGE,M6 X 1.00 X 15
051-034
LABEL, CARB EO
051-053
WIRE HARNESS
051-482
BOX. 21-3/8X15-5/8X9-1/2
051-695
AIRBOX, RAW
051-711
INSTRUCTIONS
051-922
ELBOW, AFM TO THROTTLE BODY
770-977
HOSE BARB, 1/8 NPT X 5/16
901-987
FILTER, AIR, CAI
Indented items included in the above kit
QTY.
1
2
1
1
1
6
4
1
1
1
1
1
2
2
1
1
2
1
4
1
1
1
1
1
1
1
1
Revised 02/06
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising