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Removal of Factory Intake 1. 2. Turn the ignition OFF and disconnect the vehicle’s negative battery cable. Loosen and remove the two bolts that secure the air inlet duct to the radiator core support, then remove the air inlet duct. Loosen the clamps at the air cleaner assembly and turbo inlet tube, then remove the stock intake tube. Loosen and remove the two bolts that secure the air cleaner assembly. Pull upwards to remove the air cleaner assembly. Using the bolt removed to secure the ABS control bracket. Loosen and remove the two screws that secure the mass air sensor to the air cleaner assembly, then remove the mass air sensor. Raise the vehicle and support with the jack stands, then remove the front passenger side tire. Remove the five plastic push/screw clips that secure the inner wheel house valance. Remove the 6 screw in push clips that secure the air duct to the lower valance, then remove the air duct. Remove the two remaining push clips that secure the lower valance, then pull the valance down. From inside the apron, remove the push clip that secures the apron to the upper fender. Remove the hex nut that secures the air intake resonator to the inner fender. Loosen and remove the second hex nut that secures the air intake resonator from underneath the vehicle. Remove the air intake resonator. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Install of Intake 16. Install the reducer and clamps onto the turbo and secure. 17. Loosen and remove the hex bolt on the cam cover. 18. Using the provided allen bolts, secure the mass air sensor into the adapter on the intake tube. 19. Using the allen bolts, secure the mass air sensor into the adapter on the intake tube. 20. Slide the intake tube into the reducer and secure the mass air sensor into the adapter on the intake tube. 21. Tighten the clamp on the intake tube. 22. Install the reducer and clamps onto the intake tube. 23. From underneath the vehicle loosen and remove the hex nut that secures the ABS pump to the inner fender. 24. Slide the cold air tube intake tube from underneath the vehicle into the hole in the inner fender, then line up the bracket with the ABS bolts, and tighten with the nut remove. 25. Slide the reducer onto the cold air intake tube. 26. Install the Bomz Filtercharger onto the cold air intake tube and secure with clamp. 27. Reverse the removal process for the plastic wheelhouse valance and air duct with the stock push clips. 28. Reconnect the mass air sensor electrical connection. 29. Reconnect the negative battery cable and double check to make sure everything is tight before starting the vehicle. Resetting the ECU This is to be completed at your own risk. This procedure will reset the computer so that it may “learn” of your new intake. We are not to be held liable for any mishaps that you may occur while completing this process. • • Disconnect the Negative battery cable for 5 minutes. Reconnect the battery cable and false panel cover.

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Removal of Factory Intake 1. 2. Pull upwards to remove the engine cover. Unclip the battery cover and remove, then disconnect the negative battery cable. Disengage the plastic rivet. Slide the battery cold air vent backwards and remove from the engine compartment. Disconnect the mass air sensor electrical connection. Depress the retaining clip and disconnect the rank case vent hose from the stock intake tube. Remove the switch/sensor from the air cleaner cover. Loosen the clamp at the throttle body. Unclip the coolant hose from the air cleaner cover. Unclip the air cleaner cover and remove the complete upper air cleaner assembly. Remove the rubber retainer from the core support. Remove the lower air cleaner assembly. Unclip the wire harness from the side of the battery box. Remove the mass air sensor from the air cleaner cover. Remove the plastic clip from the crank case vent on the stock intake tube. Slide the clamps off rubber rank case vent. Remove the plastic vent from the stock intake tube. Slide the plastic clip from before back onto the crank case vent. Raise the vehicle up and support by jack stands, then remove the left front tire. Remove the four bolts and one plastic rivet from the inner valance, then remove the valance. Remove the three plastic rivets and six hex bolts on the inner valance, then pull the inner valance downward. Remove the three bolts that secure the air intake resonator to the inner fender, then remove the resonator. Secure the rubber mounted stud to the hole on the battery tray. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Install of Intake 24. Install reducer and clamps onto the throttle body. 25. Install the hose onto the vent on the intake tube. 26. Install the mass air sensor into the intake tube. 27. Slide the tube into the reducer and line up the bracket with stud, then tighten the clamps at the throttle body. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Secure the switch to the bracket (not for the 06 Mazda 5 model). Install the crank case vent into the hose on the intake tube. Reconnect the crank case vent. Install the rubber mounting stud into the resonator threaded hole. Install the reducer and clamps onto the cold air tube. From underneath the vehicle install the cold air tube. Slide the cold air tube onto the short ram tube. Secure the bracket to the tuber mounted stud. Install the filter onto the cold air tube from the underneath vehicle. Reconnect the mass air sensor. Reverse the removal process and reinstall the inner fender valance. Reinstall the front tire and torque to factory specs. Slide the vent into the core support and line up the other end with the battery box and secure with plastic rivet. 41. Reconnect the negative battery cable, then reinstall the battery cover. 42. Reinstall the engine cover. Resetting the ECU This is to be completed at your own risk. This procedure will reset the computer so that it may “learn” of your new intake. We are not to be held liable for any mishaps that you may occur while completing this process. • • Disconnect the Negative battery cable for 5 minutes. Reconnect the battery cable and false panel cover.

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AIR INDUCTION SYSTEM CARBURETED Air Intake System The air intake system used on carbureted vehicles supplies fresh, filtered, temperature-controlled air to the carburetor. System consists of an air cleaner, air intake pipe, carburetor, intake manifold and intake air control system. The intake air control system maintains a uniform air temperature inside the air cleaner. Carburetor receives fresh air, controlled within a narrow temperature range, regardless of outside temperature. Carburetor Carburetor is a 2-barrel downdraft fixed venturi type. Carburetor consists of 3 layers, a choke valve and air horn make up the top layer; the venturi, float chamber, accelerator pump, actuator, and choke housing make up the middle layer; and the primary and secondary throttle valves, secondary diaphragm, and pilot screw are part of the throttle body, or bottom layer of the carburetor. FUEL INJECTION

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Page 1 CAMSHAFTS Removal 1. For access to valve covers, air intake chamber and intake air connector must be removed. See Fig. 11 . 2. Remove air cleaner hose along with upper cap on air cleaner and mass airflow meter. Disconnect necessary electrical connectors, control cables, vacuum hoses and coolant hoses for removal of air intake chamber with throttle body. 3. On models with EGR, remove nuts, EGR pipe and gaskets. On all models, remove bolts and air intake chamber support brace from air intake chamber. Remove bolts/nuts, air intake chamber and gasket. 4. Disconnect necessary electrical connectors, ground straps, vacuum hoses and wiring brackets for removal of intake air connector. Remove bolts/nuts, intake air connector and gasket. 5. Disconnect necessary electrical connectors and wiring clamps for removal of engine wiring harness assembly for access to valve covers. Remove bolts, ignition coils with spark plug wires from valve covers. Remove bolts, seal washers, valve covers and gaskets. 6. Remove timing belt and camshaft sprockets. See TIMING BELT under REMOVAL & INSTALLATION. Remove bolts, camshaft position sensor, rear timing belt cover and gaskets. See Fig. 15 . 7. To service camshafts in right cylinder head, align timing marks with 2 dots on camshaft gears by rotating camshaft using hexagonal area of camshaft. See Fig. 25 . To service camshafts in left cylinder head, align timing marks with one dot on camshaft gears by rotating camshaft using hexagonal area of camshaft. See Fig. 25 .

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REMOVAL 1. Disconnect the battery negative cable assembly from the battery negative terminal. 2. Remove the air cleaner assembly. Refer to Powertrain Management. 3. Remove the wiring harness connectors and the brackets and move aside. 4. Remove the throttle cable and the bracket from the upper intake manifold. 5. Remove the cruise control cable, (if equipped). 6. Remove the fuel lines from the intake to the rear of the block. Refer to Powertrain Management. 7. Remove the ignition coil and the bracket. Refer to Starting and Charging 8. Remove the upper intake manifold. INSTALLATION 1. Install the upper intake manifold gasket. 2. Install the upper intake manifold. Use care not to pinch the injector lines between the upper and lower intake manifolds. 3. Install the upper intake manifold bolts. Note the marks made at disassembly for proper stud location. Install the two corner studs first in order to help align the two halves. AllData Editor NOTE: Other than the two torque passes listed below, the OE Manufacturer did NOT address or supply a bolt tightening sequence for the upper Intake Manifold for this model year, or other model years where this 2 piece manifold setup is used. A “Play It Safe” final tightening sequence would be to tighten from the center most bolts to the outer most bolts. 4. Tighten the bolts in two steps: a. Tighten the bolts on the first sequence to 5 Nm (44 inch lbs.). b. Tighten the bolts on the final sequence to 10 Nm (88 inch lbs.). 5. Install the purge solenoid and bracket. Refer to Powertrain Management. 6. Install the ignition coil and bracket. Refer to Starting and Charging. 7. Install the PCV hose et the upper intake manifold. 8. Install the fuel lines from the intake at the rear of the block. Refer to Powertrain Management. 9. Install the cruise control cable (if equipped). 10. Install the throttle cable and bracket from the upper intake manifold. Refer to Powertrain Management. 11. Install the wiring harness connectors and brackets. 12. Install the air cleaner assembly. Refer to Powertrain Management. 13. Connect the battery negative cable assembly to the battery negative terminal. – Tighten the bolt to 15 Nm (11 ft. lbs.).