'98 Mazda Protege Air Intake Hose Replacement Help

protege1998

Member
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1998 Mazda Protege DX
My 1998 Mazda Protege 1.5L had cracks in the air intake hose. I ordered replacement part Dorman 696-609, which is the correct part. I took the old hose off, cleaned the MAF sensor, went to install the new hose, and realized that there was this plastic adapter pipe piece that goes in the small hole on the air intake hose (see picture links below) and which connects it to another, smaller hose.

The problem is that the little piece doesn't fit into the replacement air intake hose - the opening in the 696-609 tapers and is about 1/16th smaller than the diameter of the plastic piece. The air intake hose fits perfectly otherwise and is installed except for this connection.

The manual just calls the plastic connector an air intake pipe. As you can see from one of the pictures, I snapped off part of the middle piece of plastic trying to get it out of the original big air intake hose.

http://postimg.org/image/vv72fezeh/
http://postimg.org/image/f7xsxbepz/
http://postimg.org/image/y487ton1v/
http://postimg.org/image/y06thp2tt/

I've tried jamming the little piece into the hole and it will not fit in any shape or form.

Couple questions:

Has anybody else had this problem/is there an adapter I can get? Is there a universal part with different sized ends that would work?
What is the small hose that goes into the air intake hose?
Should I try to shave down the plastic piece so it will fit? Would this create a problem with air flow?

Any other suggestions for troubleshooting?

Thanks for the help.
 
My guess is that the tubing going to the intake snorkel is "makeup" air for the PCV system. As engine vacuum pulls crankcase vapors from the engine, fresh air to replenish the oily air has to come from somewhere. Typically, it is extracted from somewhere near the air filter.

You seem to have 3 options:
1. Belt-sand the small piece to fit in the snorkel. Apply RTV silicone around the fitting.
2. Remove the snorkel and drill a larger hole in it, making sure to clean out any chips that end up in the snorkel. Apply RTV silicone around the fitting.
3. Go directly to a dealership and get a snorkel that has the right sized hole. Sometimes mid-year changes happen, resulting (years later) in some frustration when replacement parts are needed.

Good luck.
 
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