Miata Mailing List: March 1997, Message #39
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   From: (none)

Subject: re: CAI install

   Date: (none)



Steve,



I also got my CAI from TDA and just installed it last week. Here are some

install tips:



>What shop supplies should I pick up before installing?



Just misc. wrenches, pliers, screwdrivers. Work gloves. A crimping tool.

Maybe a soldering iron. You may want a big towel or fender pad to protect

from scratches while you work.



>'apply a small amount of lubricant' what lubricant?  Brand names?



No need to be so anal about what lubricants to use: a shot of WD40 will

suffice. In this case, even spit would do the job.



>What do I do if I leak PS fluid?



Won't happen. Just slightly loosen the clamp enough to turn the hose away

and retighten.



>Do I need some kind of gasket paste/liquid in addition to the stick-on gasket?



Stick it on, tighten the bolts, voila.



>Are the instructions in the Enthusiasts manual adequate for installing the

>thermostat in a '94?



There's no need for "instructions": you pop the old thermostat out and pop

the new one in, very simple. Just make sure it's seated in the recessed lip

in the housing and facing the right direction. Just make sure the car is

cold. that coolant stays hot for a long time. Oh, and work somewhere where

it's ok for the excess coolant to drain onto the ground. And don't panic:

it will stop running out of the thermostat opening after a little while.

It's only from the top part of the engine. Once it stops draining, shove a

rag in the hole to dry up the rest so the adhesive on the new gasket will

have a dry seal when you close it up later. And be careful to scrape off

all of the old gasket to make a nice seat for the new one. Remember to top

off your radiator with the engine idling (to clear out bubbles) before

driving it again. Since it's no longer winter, it's not that critical to

worry about mixing in antifreeze when you top off the radiator, but I live

in CA where we never need the green stuff ;-D



I encountered some complications on the install on my 95, which should

apply to your 94 too. FYI, here's a copy of my note to Bill @ TDA after

installing, so he should be well aware of these issues. (I don't know if he

passed my comments on to JR for them to modify their instructions as I

suggested he do):



The CAI install instructions need revision, at least for 1995 models.

Following are the inconsistencies I came across:



1) Step 6: It was only necessary to disconnect the radiator hose on the

thermostat end and bend the hose out of the way.



2) Step 14: 95's don't have an air bag sensor under the hood latch as

described in the instructions.



3) Step 18: I found I had to saw off the plastic upper left (looking into

the engine compartment from the front of the car) radial strut supporting

the driver's side radiator fan in order to fit the airbox close enough to

the front of the car for the CAI to reach the 2 attachment holes in front

of the radiator.



4) Step 18: It's not clear how and when to use the included 2

adhesive-backed rubber washers. I adhered them to the underside of the

airbox where it attaches in front of the radiator.



5) Step 26: After mounting, the only point where the airbox was rubbing

against anything was where the steel locating bracket which holds the mass

air sensor was resting against the bottom of the thermostat housing. I cut

up and wedged a piece of rubber hose trimmed from the idle bypass hose in

between them as a cushion against vibration. Seems to be staying there so

far.



6) Step 28: I found it difficult to crimp the wire butt connectors without

accidentally cutting all the way through them. I ended up needing to solder

2 of the connections because I couldn't salvage the connectors. Perhaps the

instructions could recommend a better tool to use for crimping than what I

chose: needle-nosed pliers with wire cutting jaws.





Thanks,



Bill Wilner

Santa Monica, CA, USA



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SOCALM member and MCA member #63014.

1995 Miata, ("Pepe le Pew," license plate: "PP LE PU"), black, PEP, air.



UPGRADES SO FAR:

Black leather custom seats, 16 x 7.5 TSW Hocks, 215-40-16 Toyo T1s, Tokico

Illumina struts; Flyin' Miata springs and strut brace; Stromung cat and

dual exhaust; JR CAI and sway bars; Clutchmasters 10# aluminum billet

flywheel and kevlar clutch; TSI intakes, polished SS Hard Dog roll bar,

Robbins glass rear window



1) Anyone have a 92+ hardtop with defroster for sale or trade, preferably

black?

2) I highly recommend my local shop in Santa Monica:

Stokes Performance Center 310-393-0767/395-6204 ask for Stan or John

3) Sign my petition: "We Want Our CARB-Legal BEGI System III Turbo Kit For

1.8's and We Want It Now!" (8 strong on 2-21-97)

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