The BEGi MazdaSpeed Miata Downpipe Upgrade. Installation and operations manual Applicable to all 2004 to 2005 MazdaSpeed Miatas

Transcription

1 The BEGi MazdaSpeed Miata Downpipe Upgrade Installation and operations manual Applicable to all 2004 to 2005 MazdaSpeed Miatas Revised Rev 1.1 1

2 Thank you for purchasing the MazdaSpeed Miata Separated Gases Downpipe. We regard your installation as a mutual project and will be pleased to offer help at any time. If clarification of these instructions is required, please call BEGi at Suggestions for improvements of these instructions are welcome. Send an to info@bellengineering.net. Or, write notes on the instruction set and mail / fax to: BEGi, 203 Kestrel Dr., Spring Branch, Texas Fax: The success of this installation will be determined by a variety of factors. These instructions should be adhered to unless reasonable cause for deviation exists. The vehicle must be in excellent condition and proper tune prior to starting the installation. Care and attention to detail by the installer are of extreme importance. It is not necessary that the installer has any previous experience with forced induction. The mechanical skills required for a successful install are roughly equivalent to that needed to properly remove and replace the exhaust header and tailpipe. If one has no mechanical experience, it is strongly suggested that help be sought from a hobbyist or professional mechanic. All left or right directional references will be from the driver viewpoint. For example, the turbo mounts on the left side. These instructions and the operational requirements for this system must be reviewed with the owner-driver prior to delivery of the vehicle to the end user. Please read the statement of warranty at the end of these instructions prior to starting the installation. THE INSTALLER SHOULD PASS THESE INSTRUCTIONS ON TO THE OWNER-DRIVER. Tool and Equipment Requirements The following tools and equipment will be required to conveniently accomplish this install: General metric open/box wrenches Floor jack General SAE open/box wrenches Jack stands x 4 Assorted slot and phillips screw drivers General metric socket set & extensions Pry Bar (Small Broom Handle or Equivalent) Factory shop manual or equivalent is recommended Clean rags Spray Solvent, PB Blaster, and/or WD-40 2

3 Preliminary A clean engine is pleasant to work on. If needed, wash both top side and bottom very thoroughly. The high pressure car wash does a good job. Wearing latex gloves, can help keep the installer as clean as a nice engine. Position the car on jack stands, high enough to work conveniently beneath the car. Spray penetrating solvent on all the fasteners attaching the heat shield to the exhaust manifold. Also spray penetrating solvent (PB Blaster) on all stock downpipe, turbo bracket, and O2 sensors. Slide under the car and spray the O2 sensor and all the nut/bolt joints back to the catalytic convertor. Major items to remove Save the fasteners & gaskets, as a few will be re-used. Plastic and metal undercarriage pieces. Windshield Wiper Fluid reservoir and it s mounting bracket. There are two 12 mm fasteners. Refer to picture # 1. Exhaust manifold and downpipe heat shields. There are four heat shields to remove. Refer to picture # 1. Loosen the O2 sensor and the wire holding it in place before removing the stock downpipe tube. Use a 7/8 wrench. Refer to picture # 2. Bracket anchoring the tailpipe to the transmission. They are 17 mm fasteners. Loosen the O2 sensor under the car, located next to the catalytic convertor. Use a 7/8 wrench. Stock downpipe segment between the turbo outlet casting and stock exhaust system. These bolts are 14 mm, and there are three to remove in the front and two in the rear. Bracket connecting the turbo to the block of the car. The three bolts are 14 mm s also. This is easier to reach thru the driver side wheel well area. Stock turbine outlet casting. These bolts are 12 mm, and there are four to remove. Be very careful not to break the studs on the turbo when removing the cast elbow. However, since the possibility exists that a stud will come out or break, we have included four new 8 mm studs, 5/16 SAE washers, and 8 mm mechanical locking nuts. Refer to picture # 3. Figure 4Picture # 1 Figure 5Picture # 2 Figure 6Picture # 3 3

4 Installation of Parts Due to the cumbersome configuration of the downpipe, it must be installed in the following sequence. You will reuse stock gasket at the turbo to downpipe joint. BEGi has supplied you with a new gasket to replace the donut gasket at the rear of the downpipe 1. Place the upper section of the downpipe into position on the turbine outlet studs, from underneath the car. Reuse the stock gasket. This part of the install will require some finesse, patience and/or persuasion. Work the downpipe upwards, as indicated in picture # 4. Then rotate the downpipe, as indicated in picture # 5. Place the downpipe onto the studs at the turbo. When the downpipe is sitting on the turbine outlet studs and does not hit the transmission or frame of the car, place two 8 mm nuts on the studs to hold the downpipe into place. Figure 8Picture # 4 Figure 7Picture # 5 2. Push the two sections of the downpipe together at the swage. Line up the bolt hole guides. Install 1/4-20 x 4" cross bolt and the mechanical lock nut to secure it together. The hex head portion of the bolt should be positioned towards the front of the car. Refer to picture # 6. Figure 10Picture # 6 Figure 9Picture # 7 3. With the downpipe in place and cross bolt secured, line up the back portion of the downpipe at the stock exhaust system. Replace the stock donut gasket with the new gasket provided. Fasten securely with new 10 mm bolts provided. Refer to picture # 7. 4

5 4. Add remaining washers and nuts to the turbine outlet studs, fastening the downpipe to the turbo. 5. Install the O2 sensors into the bungs on the downpipe by the exhaust manifold and catalytic convertor. Twisting the wire up counter clockwise about six revolutions before engaging the threads will avoid the wire having to live with a straining twist. Make sure that the O2 sensor or wires do not rub on anything, nor cause interference. Refer to picture # 8. If installing a wideband O2 sensor, it will install before the catalytic convertor and the 2nd stock sensor will install post convertor. 6. Insert the 18mm x 1.5 hex plug into the third O2 sensor bung. If you are installing a wideband O2 reader or controller, it will install here instead of the plug. Refer to picture # Replace the stock heat shields that attach to the turbo and exhaust manifold. Use the original fasteners. Refer to picture # Screw the coiled wire, holding the O2 sensor wire, back onto the exhaust manifold heatshield. Refer to picture # 2 on page 3. Make sure the O2 sensor wire does not come in contact with the exhaust manifold or EGR. Figure 11Picture # 8 Figure 12Picture # 9 Figure 13Picture # 10 PLEASE REVIEW THE INSTALLATION AS ACCOMPLISHED THUS FAR. WHEN SATISFIED THAT ALL ITEMS ARE IN PROPER ORDER, PROCEED TO TUNING AND TESTING. Testing procedures Caution: Due to the sparse sound insulation on the Miata, knock is difficult to hear. Pay extreme attention to the sound of detonation, as it is very damaging to the motor. If knock is detected lift off the throttle immediately. Always test with the windows up and accessories off for the best audible detection of any knocking sounds. Start the engine and check for exhaust leaks. Correct as required. Do not be alarmed by acrid fumes coming from the turbo and manifold area. This is the heat burning oily hand prints off the hot surfaces. Drive about twenty miles and the fumes should be gone. However, if it smells like plastic or rubber melting/burning, check to make sure the O2 sensor wire by the exhaust manifold is not touching the EGR fitting. Review the instructions and installation for any details overlooked and correct as required. 5

6 General rules of operation Use premium octane fuel at all times. Higher, if available. Lesser octane fuels can be used successfully, but will require minor tuning changes. All generic programming is based on 92/93 octane fuels. Do not apply maximum boost for more than 30 second durations. If any sounds of rough combustion occur, cease using boost until the cause is identified and corrected. It is the responsibility of the installer to review these general rules of operation with the owner/driver. WARRANTY INFORMATION All items made by BEGi are warranted for workmanship and function for one year from the date of receipt. All other items are subject to manufacturer s warranty. If problems arise from using a BEGi part in a manner other than intended, or a part is installed incorrectly, BEGi reserves the right to refuse warranty coverage for damages. BEGi will not warranty any kits, parts or items purchased thru an online auction that is not purchased from an authorized dealer. The customer must be able to provide proof of purchase for any warranty repairs. BEGi reserves the right to inspect any item before any warranty will be granted. BEGi will not reimburse for any labor charges on warranty items that occur without prior, written consent. BEGi extends no warranty nor accepts liability to any original, stock, or replacement components on the vehicle. Warranty may transfer. BEGi must be notified within twenty days of sale to continue warranty coverage. Shipping / freight charges are the responsibility of the end user for all warranty consideration. Terms of Sale All shortages from the parts list must be reported to BEGi within 20 days of receipt. BEGi does not pay any towing expenses. All returned items are subject to a 25% re-stocking fee. BEGi accepts no liability for death or injury to any person or persons under any circumstance. The re-seller assumes all responsibility for the end user s knowledge of this warranty. Turbo Kits sold by BEGi or by a BEGi authorized distributor must be registered with BEGi within twenty days of receipt by the end user. BEGi does not guarantee that these parts kits will pass smog tests. For California residents, some BEGI parts have been provided a C.A.R.B. Executive Order Number. However, BEGi does not guarantee that the end user s car will pass. Acceptance, re-sell, or use of any BEGi part constitutes full agreement by the re-seller/end user, that the terms of sale and warranty are fully understood and accepted in full. BEGi does not pay any towing expenses. BEGi will not pay your speeding tickets. Copyright BEGi