Installation Manual

ManualsBrandsK&N ManualsAir IntakeK&N 57-0615 57i High Performance International Intake Kit

Technical Support: eindhoven.tech@knfilters.com

www.knfilters.com UK technical enquiries: phone the R&D department at 01925-635950,

Mon-Thu from 8:30 am to 5pm

WARNING: Before starting the

engine carry out a final fitment check

of the K&N performance kit. It will be

necessary for all intake systems to

be checked periodically for

realignment, clearance and

tightening of all connections. Failure

to follow the above instructions or

proper maintenance may void the

warranty.

FILTER MAINTENANCE: K&N

suggests checking the filter periodi-

cally for excessive dirt build-up.

When the element becomes covered

in dirt (or once a year), service it

according to the instructions on the

Recharger service kit available from

your K&N dealer, part number 99-

5000 or 99-5050.

Parts list:

1x Air Filter.

1 x Rubber Filter Adaptor.

1 x Silicone Adaptor Hose.

1 x Plastic Molded Intake Pipe.

1 x Flexi Cold Air Hose.

1 x Literature Pack.

Fixing Kit :-

1xClamp; 100-120mm Std.

2 x #44HoseClamp.

5xPlasticTie.

1 x Foam Gasket.

1 x Barbed Vent Adaptor.

1 x Breather Hose.

2xSelfTapScrew.

1 x M5PanHeadScrew..

Kit Number 57-0615

Mazda 6, 1.8L/2.3L L4 16v, 118/164 bhp, Mar 2002 - «

Instruction sheet A2054-666

1. Disconnect the negative terminal from the vehicle battery.

2. Remove the plastic engine cover. (Fig. 1)

3. Remove the engine breather hose from the metal breather pipe. (Fig. 2)

4. Remove the solenoid valve from the side of the rubber intake hose. (Fig. 3)

5. (2.3L models only) Disconnect the green electrical harness plug from the vacuum solenoid located

at the side of the air box assembly. (Fig. 4)

6. (2.3L models only) Remove the vacuum hose from the front of the air box assembly as shown.

(Fig. 5)

7. Unclip & remove the rubber intake hose from between the air box lid & throttle housing. (Fig. 6)

8. Unclip & remove the electrical harness plug from the MAS (Mass Air Sensor). Carefully lift the

complete air box assembly out of its mounting rubbers & carefully remove the air box assembly

from the vehicle (Fig. 7)

9. (2.3L models only) Follow the vacuum hose from instruction #5 & remove the hose from the inlet

manifold. (Fig. 8)

10. (2.3L models only) Remove the vacuum elbow hose from the one-way valve as shown. (Fig. 9)

11. (2.3L models only) Insert the M5 pan head screw into the end of the vacuum elbow hose. (Fig.10)

12. (2.3L models only) Refit the vacuum elbow hose to the tube on the inlet manifold. (Fig.11)

13. Carefully unscrew & remove the MAS from the air box assembly. (Fig.12)

14. Stick the foam gasket to the hole located on the new molded intake pipe. Fit the MAS to the

hole in the molded intake pipe & secure using the screws supplied. (Fig.13&14)

15. Assemble the new molded intake pipe using the silicone adaptor hose & rubber filter adaptor.

(Fig.15)

16. Secure the new intake pipe assembly to the throttle housing using the silicone adaptor hose

& hose clips supplied. (Fig.16&17)

17. Slide the new filtercharger onto the rubber filter adaptor & tighten the hose clip supplied.

(Fig.18&19)

18. Fit the new silicone breather hose to the metal breather pipe. (Fig.20)

19. Insert the straight barbed vent adaptor into the end of the new silicone breather hose. (Fig.21)

20. Insert the new breather hose / barbed vent adaptor into the hole in the base of the filtercharger.

(Fig.22)

21. Reconnect the electrical harness plug to the MAS. (Fig.23)

22. Secure any excess harnesses with the plastic ties supplied. (Fig.24)

23. Secure the solenoid valve using a plastic tie supplied. (Fig.25)

24. Taking all the necessary safety precautions as per manufacturers instructions raise the front of

the vehicle. Secure the hose to the lower spoiler / under tray using the plastic ties supplied.

(Fig.26)

25. 3RVLWLRQWKHRWKHUHQGRIWKHKRVHWRILQLVKDSSUR[´FPIURPWKHILOWHUFKDUJHUVHFXUH

using a plastic tie supplied. (Fig.27)

26. Refit the plastic engine cover.

27. Reconnect the negative battery terminal.

28. Carry out a final check of the height / alignment of the K&N induction system before starting the

engine. Installation is now complete. (Fig.28)

Fig. # 1

Fig. # 2

Fig. # 3

Fig. # 4

Fig. # 5

Fig. # 6

Fig. # 7

Fig. # 8

Summary of content (5 pages)

PAGE 1
Kit Number 57-0615 Mazda 6, 1.8L/2.3L L4 16v, 118/164 bhp, Mar 2002 - « Instruction sheet A2054-666 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Disconnect the negative terminal from the vehicle battery. Remove the plastic engine cover. (Fig. 1) Remove the engine breather hose from the metal breather pipe. (Fig. 2) Remove the solenoid valve from the side of the rubber intake hose. (Fig. 3) (2.
PAGE 2
57-0615 A2054-666 Fig. # 9 Fig. # 13 Fig. # 11 Fig. # 10 Fig. # 15 Fig. # 14 Fig. # 12 Fig. # 16 Fig. # 18 Fig. # 19 Fig. # 20 Fig. # 21 Fig. # 22 Fig. # 23 Fig. # 24 Fig. # 25 Fig. # 26 Fig. # 17 www.knfilters.com Fig. # 27 Fig. # 28 Technical Support: eindhoven.tech@knfilters.
PAGE 3
Artikelnummer 57-0615 Mazda 6, 1.8L/2.3L L4 16v, 120/166 pk, 2002-2005 Instructieblad No. A2054-666 1. 2. 3. 4. 5. 7. 7. 8. (Fig. 1) (Fig. 2) (Fig. 3) (Fig. 4) (Fig. 5) (Fig. 6) (Fig. 7) 9. (Fig. 8) 10. (Fig. 9) 11. (Fig. 10) 12. (Fig. 11) 13. (Fig. 12) 14. (Fig.13) (Fig.14) 15. (Fig. 15) 16. (Fig.16) (Fig.17) 17. (Fig.18) (Fig.19) 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. (Fig. 20) (Fig. 21) (Fig. 22) (Fig. 23) (Fig. 24) (Fig. 25) (Fig.
PAGE 4
Artikelnummer 57-0615 Mazda 6, 1.8L/2.3L L4 16v, 120/166 PS, 2002-2005 Instruktionsblatt No. A2054-666 1 2 3 4 5 (Fig. 1) (Fig. 2) (Fig. 3) (Fig. 4) 6 (Fig. 5) 7 (Fig. 6) 8 (Fig. 7) 9 (Fig. 8) 10 (Fig. 9) 11 (Fig. 10) 12 (Fig. 11) 13 (Fig. 12) 14 (Fig.13) (Fig.14) 15 (Fig. 15) 16 (Fig.16) (Fig.17) 17 (Fig.18) (Fig.19) 18 19 20 21 22 23 24 (Fig. 20) (Fig. 21) (Fig. 22) (Fig. 23) (Fig. 24) (Fig. 25) (Fig. 26) Teile Nehme den Schlüssel aus dem Kontaktschloß und klemme das Minuskabel der Batterie ab.
PAGE 5
Kit référence 57-0615 Mazda 6, 1.8L/2.3L L4 16v, 120/166 ch, 2002-2005 Feuille d'instructions No. A2054-666 1. 2. 3. 4. 5. (Fig. 1) (Fig. 2) (Fig. 3) (Fig. 4) 6. (Fig. 5) 7. (Fig. 6) 8. (Fig. 7) 9. (Fig. 8) 10. (Fig. 9) 11. (Fig. 10) 12. (Fig. 11) 13. (Fig. 12) 14. (Fig.13) (Fig.14) 15. (Fig. 15) 16. (Fig.16) (Fig.17) 17. (Fig.18) (Fig.19) 18. 19. 20. 21. 22. 23. 24. (Fig. 20) (Fig. 21) (Fig. 22) (Fig. 23) (Fig. 24) (Fig. 25) (Fig. 26) 25. (Fig. 27) 26. 27. 28. (Fig.