Miata Mailing List: March 1997, Message #56
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   From: (none)

Subject: Re: CAI install on '95

   Date: (none)



Bill Wilner posted these notes on the CAI and the 95s this afternoon and I

installed mine this morning... I discovered the same stuff the hard way.  I'm

an average backyard mechanic who follows good directions pretty well.  I've

noted a couple of other things and inserted them in Bill's observations....



In a message dated 97-03-01 16:39:56 EST, Bill wrote:



<< 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.



..but it was easy to do so I took it entirely off and it made life simple

and I cleaned it while it was off.

 

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

 described in the instructions.



..but I sure looked for it! 



 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.



..facing the car, the one on the left was not problem; I enlarged the hole

about 1/4 inch to reach the one on the right...easier than cutting the

aforementioned radiatior strut or housing.  I'm hoping that the slack I

created will also help avoid the all too common plastic cracking near that

right hole over time.  



..what was a problem is that I had to relocate the Windshield washer filler

neck to the extreme right side of the access hole.  This involved unscrewing

the existing securing nut and using a large plastic tie to secure it toward

the right side of the hole...seems to be a good fix. 

 

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.

 

..It's not even mentioned but that's where I put mine too.



 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.



..mine touches too, good idea.

 

 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.

 

..I used a crimping tool...no problem.  Heat shrink was a neat idea but my

hair dryer must not have been hot enuf.  No biggy.



..I found the direction to work the PS bracket/hose issues out of sequence.

 It was whole lot easier to get to them after I removed the stock air box,

et. al.



..I found I did not have to bend the PS hose bracket or rotate the hose at

all... of course I found this after I had already done it.



..The instructions make reference to "it is good to have a Miata manual of

some sort" to refer to.  



..The sequence I used was:  1. read the directions,  2. looked up the

appropritate page in the shop manual and wrote its number next to the

direction step for reference...I also read the info as I looked it up,  3.

 Stood in front of the car with the hood up and eyeballed each step.  Now, I

did all this last night so I was pretty ready whenever a glitch occurred this

morning...and they did...like being smart enuough to remove the airbox,

et.al. before messing with the power steering adjustments.



Oh, I also had to cut one hose to get a better/nicer fit from the throttle

body to the CAI.  Idle-bypass?



After all this imersion, I think I could do it again without directions and

much quicker.



Thanks,

 

Bill Wilner

Santa Monica, CA, USA



..as amended by Bob Hotaling, Altamonte Springs, FL, USA

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