3G Protege (non-turbo): OBX (ebay) Intake Installation
February-6th-2003, 10:42 PM
#1
Clean-Up Crew
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Join Date: Jan 2003
Location: Pleasure Point, Ca.
Posts: 2,360
3G Protege (non-turbo): OBX (ebay) Intake Installation
I just bought an intake off of ebay and it came with idiot proof installation instructions. I haven't seen instructions this explanatory posted.
Here they are word for word.
INSTALLATION GUIDE FOR OBX INTAKE-
2000-03 MAZDA PROTEGE 2.0L DOHC (NON TURBO)
Required Tools/Items:
1. Standard (Flat Head) Screw Driver
2. Medium Philips (Cross Type) Screw Driver
3. 10mm Socket and Socket Wrench
4. 10mm Open End Wrench
5. Thread Locking Compound
6. (1) Zip Tie
Vehicle engine should be off. It should also be cool to the touch with the parking brake set. Finally the Negative (-) terminal on the battery should be disconnected and out of the way.
Note: During this installation, it is a good idea to use the appropriate safety gear, such as eye/hand protection. Always be mindful of state and local laws before making any modification to your vehicle.
During this installation we will be doing the following:
1. Removal of the Factory intake, air filter, and cold air box
2. Installing the OBX Race Tuned Replacement
3. Installing the Vacuum Breather Hose and Repositioning the Purge Solenoid
4. Securing the OBX Intake
5. Start the Vehicle and have Fun!
Step 1: Removal of the Factory Intake, Air Filter, and Cold Air Box
1. Disconnect the electrical connector on the MAS (MAF) unit.
2. Disconnect the electrical connector on the IAT sensor. (Small sensor located on the air filter cover)
3. Loosen the clamp on the MAS unit. (Medium Philips Screw Driver)
4. Remove the air tube from the MAS unit.
5. Removal of air filter cover:
- Unlatch the 2 straps on the air filter cover.
- Gently lift off the air filter cover/MAS unit.
- Remove the wire harness clip attached to the air filter cover.
- Set the air filter cover aside.
6. Remove the factory air filter.
7. Removal of the lower air filter housing:
- Remove the rear 10mm nut attaching the lower air filter housing. (Do not discard this nut. It will be used to mount the new bracket in a later step)
- Remove the side 10mm attachment bolt next to the radiator overflow reservoir.
- Lift out the lower air filter housing.
8. Separation of the purge solenoid and the rear air tube:
- Pull straight up on the purge solenoid & bracket until the bracket slides out of the air tube. Be careful not to pull off or damage the hoses & wires on the purge solenoid.
- Push the solenoid out of the way until after the installation of the air intake. The solenoid will get Zip Tied in a later step.
9. Disconnect the breather hose from the engine port & the air tube port. Remove the plastic ratchet clip from the breather hose. Remove the breather hose.
10. Loosen the clamp on the throttle body end of the rear tube (Medium Philips Screw Driver) and remove the air tube.
11. Removal of the front cold air box: (above the radiator)
- Remove the 2 front 10mm nuts
- Remove the 2 lower 10mm bolts that are located next to the radiator overflow reservoir.
- Remove the cold air box.
Step 2: Installing the OBX Race Tuned Intake Replacement
(All hose clamps require the Standard screw driver during this step)
1. Assemble the small OBX boot on the long OBX intake tube closest to the vacuum port. Add and tighten the clamp.
2. Assemble a large OBX boot on the opposite end of the long intake tube. Add and tighten the clamp.
3. Add the clamp on the small boot (throttle body end) and assemble the long OBX intake tube onto the throttle body. Make sure the boot is seated all the way until it bottoms out on the throttle body. Snug the clamp.
4. Removal of the MAS unit from the factory air filter cover:
- Make note which direction the MAS unit flows. This sensor must flow the exact direction as the factory air tube.
- Remove the 2 side 10mm bolts on the MAS unit. (Do not discard the bolts. One bolt will be used to mount the new bracket in a later step)
- Remove the MAS unit by gently removing it from the cover.
- Remove the rubber seal attached to the MAS unit.
5. Install the MAS unit onto the installed OBX intake tube with a clamp. Make sure the direction this sensor flows is the same as the factory direction. Make sure the boot is seated all the way so it bottoms out on the MAS unit. Tighten the clamp.
6. Assemble a large OBX boot on the short OBX intake tube closest to the rubber grommet. Add the tighten the clamp.
7. Install the Air Filter onto the opposite end of the short intake tube. Tighten the clamp.
8. Gently pull out the IAT sensor from the factory air filter cover. Install the IAT sensor into the short OBX intake tube grommet. (Near the air filter)
9. Add a clamp and install the short intake tube w/filter onto the MAS unit. Make sure the boot is seated all the way so it bottoms out on the MAS unit. Angle the air filter approximately 45 degrees facing down and tighten the clamp.
10. Go back and re-tighten all the hose clamps. (7 total)
Step 3: Installing the Vacuum Breather Hose and Repositioning the Purge Solenoid
1. Locate the colored breather hose provided with the kit.
2. Install the colored breather hose by connecting it on the engine port. Connect the opposite end of the colored breather hose to the OBX intake tube port. Cut the hose to length is desired.
3. Zip Tie the purge solenoid and bracket upright to the closest electrical harness bundle. The purge solenoid needs to be facing upright like the factory position. Make sure the hoses and the wires on the purge solenoid are clear of the throttle body linkage.
Step 4: Securing the OBX Intake
1. Locate the 'L' shaped piece of metal (bracket) supplied in your kit.
2. Make a 90 degree bend on the bracket, at the second hole after the slot.
3. Attach the bracket to the stud located on the battery tray using the first hole after the slot. Use the 10mm nut from Step 1:7. Snug the nut enough so adjustment can still be made. (Use thread locking compound on the stud and nut)
4. Attach the opposite end of the bracket (The end with the 'L' shape) to the rear MAS unit attachment hole. Use the 10mm bolt from Step 2:4. Snug the bolt (10mm Open End Wrench) enough so adjustment can still be made. (Use thread locking compound on the bolt threads)
5. Check for clearance between the metal OBX intake tube and the Brake Master Cylinder & Brake Tubes.
Adjust the bracket for more clearance. The metal OBX intake tube should not interfere with the Brake Master Cylinder or Brake Tubes under engine load. Tighten the nut and bolt when clearance is achieved. IMPORTANT: if there is contact between the OBX intake tube and the Master Cylinder or Brake Tubes, brake failure may occur. Double check for clearance after tightening the bracket. If more clearance is needed, adjust the bracket again and re-tighten the nut and bolt.
Step 5: Start the Vehicle and have Fun!
1. Check the tubes, vacuum hose, clamps, nut and bolt to verify they are secure.
2. Plug the MAS unit and IAT sensor back in.
3. Reattach the Negative (-) terminal on the battery.
Here they are word for word.
INSTALLATION GUIDE FOR OBX INTAKE-
2000-03 MAZDA PROTEGE 2.0L DOHC (NON TURBO)
Required Tools/Items:
1. Standard (Flat Head) Screw Driver
2. Medium Philips (Cross Type) Screw Driver
3. 10mm Socket and Socket Wrench
4. 10mm Open End Wrench
5. Thread Locking Compound
6. (1) Zip Tie
Vehicle engine should be off. It should also be cool to the touch with the parking brake set. Finally the Negative (-) terminal on the battery should be disconnected and out of the way.
Note: During this installation, it is a good idea to use the appropriate safety gear, such as eye/hand protection. Always be mindful of state and local laws before making any modification to your vehicle.
During this installation we will be doing the following:
1. Removal of the Factory intake, air filter, and cold air box
2. Installing the OBX Race Tuned Replacement
3. Installing the Vacuum Breather Hose and Repositioning the Purge Solenoid
4. Securing the OBX Intake
5. Start the Vehicle and have Fun!
Step 1: Removal of the Factory Intake, Air Filter, and Cold Air Box
1. Disconnect the electrical connector on the MAS (MAF) unit.
2. Disconnect the electrical connector on the IAT sensor. (Small sensor located on the air filter cover)
3. Loosen the clamp on the MAS unit. (Medium Philips Screw Driver)
4. Remove the air tube from the MAS unit.
5. Removal of air filter cover:
- Unlatch the 2 straps on the air filter cover.
- Gently lift off the air filter cover/MAS unit.
- Remove the wire harness clip attached to the air filter cover.
- Set the air filter cover aside.
6. Remove the factory air filter.
7. Removal of the lower air filter housing:
- Remove the rear 10mm nut attaching the lower air filter housing. (Do not discard this nut. It will be used to mount the new bracket in a later step)
- Remove the side 10mm attachment bolt next to the radiator overflow reservoir.
- Lift out the lower air filter housing.
8. Separation of the purge solenoid and the rear air tube:
- Pull straight up on the purge solenoid & bracket until the bracket slides out of the air tube. Be careful not to pull off or damage the hoses & wires on the purge solenoid.
- Push the solenoid out of the way until after the installation of the air intake. The solenoid will get Zip Tied in a later step.
9. Disconnect the breather hose from the engine port & the air tube port. Remove the plastic ratchet clip from the breather hose. Remove the breather hose.
10. Loosen the clamp on the throttle body end of the rear tube (Medium Philips Screw Driver) and remove the air tube.
11. Removal of the front cold air box: (above the radiator)
- Remove the 2 front 10mm nuts
- Remove the 2 lower 10mm bolts that are located next to the radiator overflow reservoir.
- Remove the cold air box.
Step 2: Installing the OBX Race Tuned Intake Replacement
(All hose clamps require the Standard screw driver during this step)
1. Assemble the small OBX boot on the long OBX intake tube closest to the vacuum port. Add and tighten the clamp.
2. Assemble a large OBX boot on the opposite end of the long intake tube. Add and tighten the clamp.
3. Add the clamp on the small boot (throttle body end) and assemble the long OBX intake tube onto the throttle body. Make sure the boot is seated all the way until it bottoms out on the throttle body. Snug the clamp.
4. Removal of the MAS unit from the factory air filter cover:
- Make note which direction the MAS unit flows. This sensor must flow the exact direction as the factory air tube.
- Remove the 2 side 10mm bolts on the MAS unit. (Do not discard the bolts. One bolt will be used to mount the new bracket in a later step)
- Remove the MAS unit by gently removing it from the cover.
- Remove the rubber seal attached to the MAS unit.
5. Install the MAS unit onto the installed OBX intake tube with a clamp. Make sure the direction this sensor flows is the same as the factory direction. Make sure the boot is seated all the way so it bottoms out on the MAS unit. Tighten the clamp.
6. Assemble a large OBX boot on the short OBX intake tube closest to the rubber grommet. Add the tighten the clamp.
7. Install the Air Filter onto the opposite end of the short intake tube. Tighten the clamp.
8. Gently pull out the IAT sensor from the factory air filter cover. Install the IAT sensor into the short OBX intake tube grommet. (Near the air filter)
9. Add a clamp and install the short intake tube w/filter onto the MAS unit. Make sure the boot is seated all the way so it bottoms out on the MAS unit. Angle the air filter approximately 45 degrees facing down and tighten the clamp.
10. Go back and re-tighten all the hose clamps. (7 total)
Step 3: Installing the Vacuum Breather Hose and Repositioning the Purge Solenoid
1. Locate the colored breather hose provided with the kit.
2. Install the colored breather hose by connecting it on the engine port. Connect the opposite end of the colored breather hose to the OBX intake tube port. Cut the hose to length is desired.
3. Zip Tie the purge solenoid and bracket upright to the closest electrical harness bundle. The purge solenoid needs to be facing upright like the factory position. Make sure the hoses and the wires on the purge solenoid are clear of the throttle body linkage.
Step 4: Securing the OBX Intake
1. Locate the 'L' shaped piece of metal (bracket) supplied in your kit.
2. Make a 90 degree bend on the bracket, at the second hole after the slot.
3. Attach the bracket to the stud located on the battery tray using the first hole after the slot. Use the 10mm nut from Step 1:7. Snug the nut enough so adjustment can still be made. (Use thread locking compound on the stud and nut)
4. Attach the opposite end of the bracket (The end with the 'L' shape) to the rear MAS unit attachment hole. Use the 10mm bolt from Step 2:4. Snug the bolt (10mm Open End Wrench) enough so adjustment can still be made. (Use thread locking compound on the bolt threads)
5. Check for clearance between the metal OBX intake tube and the Brake Master Cylinder & Brake Tubes.
Adjust the bracket for more clearance. The metal OBX intake tube should not interfere with the Brake Master Cylinder or Brake Tubes under engine load. Tighten the nut and bolt when clearance is achieved. IMPORTANT: if there is contact between the OBX intake tube and the Master Cylinder or Brake Tubes, brake failure may occur. Double check for clearance after tightening the bracket. If more clearance is needed, adjust the bracket again and re-tighten the nut and bolt.
Step 5: Start the Vehicle and have Fun!
1. Check the tubes, vacuum hose, clamps, nut and bolt to verify they are secure.
2. Plug the MAS unit and IAT sensor back in.
3. Reattach the Negative (-) terminal on the battery.
Last edited by eggynatey; February-18th-2003 at 05:04 PM.
April-2nd-2003, 05:44 PM
#3
Clean-Up Crew
Thread Starter
Join Date: Jan 2003
Location: Pleasure Point, Ca.
Posts: 2,360
No, I didn't have to move it at all. The OBX is a short ram intake, so the filter should almost butt up against the res., but not quite touch it. For an Injen (or any) CAI you would have to move it. I think the Injen even comes with a bracket to move the res. over a little. It's really easy and straightfoward.
Mine fits kinda like this, although this guy's is touching the radiator hose and that's no good either. You just gotta fiddle with it so that it clears everything.:
Mine fits kinda like this, although this guy's is touching the radiator hose and that's no good either. You just gotta fiddle with it so that it clears everything.:
Last edited by eggynatey; April-2nd-2003 at 05:46 PM.
May-13th-2003, 12:36 AM
#6
Registered User
Join Date: Apr 2003
Location: Prescott Valley, Az
Posts: 85
I bought a Mazda Protege 2.0L Polished Intake Kit with K&N Filter from dohccivicna1250(7175) on ebay.
They sent me the wrong parts. Stubborn me made them fit.
I used the stock pieces from the engine to the air sensor. Then I replaiced the air box with the polished 90 degree elbow and put the K&N filter on the other end.
Now the check engine light is on and the car won't idle. It bogs until 5500 RPS then bogs again at 6000.
Do I need to reset the ECU?
If so how do I do it?
Any suggestions on how to fix this?
Later,
Bill
They sent me the wrong parts. Stubborn me made them fit.
I used the stock pieces from the engine to the air sensor. Then I replaiced the air box with the polished 90 degree elbow and put the K&N filter on the other end.
Now the check engine light is on and the car won't idle. It bogs until 5500 RPS then bogs again at 6000.
Do I need to reset the ECU?
If so how do I do it?
Any suggestions on how to fix this?
Later,
Bill
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