The Begi M2 Miata Exhaust Manifold. Installation and Operations Manual Applicable to all 1999 to 2005 Mazda Miata. Revised Version 1.

Transcription

1 The Begi M2 Miata Exhaust Manifold Installation and Operations Manual Applicable to all 1999 to 2005 Mazda Miata Revised Version 1.1 1

2 Thank you for purchasing the BEGi Exhaust Manifold. 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 ownerdriver 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 Clean rags General SAE open/box wrenches WD-40 Spray or Similar Assorted slot and phillips screw drivers General metric socket set Factory shop manual or equivalent is recommended Wire brush 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. Spray penetrating solvent on all the fasteners attaching the heat shield to the exhaust manifold. 2

3 Major items to remove Save the fasteners, hose clamps and turbo hose, as they will be re-used. Exhaust manifold heat shield. Refer to picture # 1. Exhaust manifold. Clean the head face with a scraper and solvent. Stuff the exhaust ports with rags. Keep in mind that two of the exhaust valves are open all the time. If you have a turbo installed already: Remove the turbo heatshield, compressor outlet tube, compressor inlet tube, downpipe and turbo. It may be possible to remove the turbo and set it aside without having to remove all of the water and oil lines. Picture # 1 Installation of Parts Exhaust Manifold: Bag # Inspect the inside of the exhaust manifold (61002 or for 02 only) for debris. Clean as necessary. Refer to picture # 2. Wrenching a stud into a threaded recess is easily done by jamming two nuts together on the outer end of the stud and wrenching the stud firmly into position with the outer nut. Then un-jam and remove the nuts. Refer to picture # 3. Install the 10mm x 30mm studs into the turbo side flange on the manifold. Use the double nut jam. No Loctite or such is needed, as it would not survive the heat. The shorter threaded end goes into the manifold. Picture # 2 Note: Tighten the stud in the manifold about half that with which you would tighten the nut alone. This preload is actually what gives the stud its magic fastening characteristics. Turbocharger, Downpipe & Manifold Installation: Bag # These three items must be installed in this sequence: Picture # 3 1. Lay the downpipe in place 2. Install the exhaust manifold 3. Install the turbo The downpipe must be installed from beneath the car. Wiggle it into position and engage the studs at the catalytic converter. Add the nuts, but leave them loose. Place the manifold onto the head. Reuse the original manifold to head gasket. It is stainless, virtually indestructible and entirely reuseable. Tidy it up a bit with solvent or the scotch brite pad, if Picture # 4 Picture # 5 3

4 needed. Refer to picture # 4. Bolting up the manifold can be a bit dicey. The center nut can only be started with the manifold still pulled away from the head. It is necessary to start the center nut first due to limited clearance. Engage it and only turn it two or three revolutions. Once the center nut is engaged, engage the EGR tube with one revolution only. Add remaining manifold to head nuts and tighten. Now tighten the EGR tube. The 2002 Miatas have a female EGR fitting. Refer to picture # 5. Note: There is very purposely no gasket in the joint between turbo and manifold. The turbo and downpipe must be engaged simultaneously with the exhaust manifold. While a bit trickey, fumble around for about a minute and it will all virtually leap together and onto the manifold. Add the mechanical lock nuts and washers, but Do not tighten anything yet. When tightening all the fasteners involved, it MUST be done in the following sequence. If the sequence is not followed, the convertor will wind up touching the bottom of the car and roasting your feet. 1. Turbo to downpipe 2. The downpipe to the catalytic convertor 3. Turbo to manifold Re-install the compressor inlet and outlet tubes. Secure all water and oil lines to the turbo. Re-install turbo heatshield. 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. Drive the car a few miles prior to applying boost. If all systems are operating normally, proceed with the testing. Generally use 3rd or 4th gears to keep events at a slower pace. Apply boost in small increments at a time such that no sudden changes occur. 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. Review the instructions and installation for any details overlooked and correct as required. 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. 4

5 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. BEGi does not pay any towing expenses. 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. 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. Copyright BEGi