The BEGi 1.6L & 1.8L Mazda Miata Oil Drain Line. Installation and Operations Manual Applicable to all 1990 to1997 Mazda Miatas

Transcription

1 The BEGi 1.6L & 1.8L Mazda Miata Oil Drain Line Installation and Operations Manual Applicable to all 1990 to1997 Mazda Miatas Revised Rev 1.1 1

2 STOP! Please do both of us a favor and inventory all components of the system. Do this prior to starting the installation. BEGI must be informed of missing items within 20 days. We will not ship items to you overnight, even if you are in the middle of an installation. Prior to starting the installation, fill the fuel tank with gasoline of 93 octane. Do not dilute with lesser octane fuel already in the tank. Please read the statement of warranty at the end of these instructions prior to starting the installation. Unless the fuel filter, spark plugs and plug wires are all relatively fresh (less than 10k miles) they should also be changed. 2

3 Thank you for purchasing this system. We regard your installation as a mutual project and will be pleased to offer help at any time. We remain committed to make this a successful and enjoyable experience for all concerned. If any questions arise in the process of installation, please feel free to call BEGi for assistance. 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. The daily operator of the vehicle must become familiar with, and observe all operational guidelines. 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. Clean and inspect all components of this assembly, as BEGi accepts no responsibility for cleanliness. All components will be cleaned prior to shipment, however, the cleanliness standards of the installer override all others. All components should be inventoried with respect to the packing lists. Shortages will not be honored in excess of twenty days after the shipping date. BEGi is not responsible for fits relative to other aftermarket components. All left or right directional references will be from the driver viewpoint. For example, the turbo mounts on the left side. 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: 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 Vehicle Service Updates This installation process calls for an oil and filter change. We strongly urge the use of synthetic lubricants, such as Amsoil. Copyright BEGi

4 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 Hand drill and assorted bits Permatex Thread Sealer Spray Solvent - 1 can Mineral Spirits - 1 pint Oil change & Filter Oil drain pan Clean rags Small funnel 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 stay clean, as well as a clean engine. Position the car on jack stands, high enough to work conveniently beneath the car. Remove the cable from the negative terminal at the battery. DO NOT DRAIN THE OIL. Major Items to Remove Save the fasteners, as a few will be re-used. Remove the current oil drain line hardware Installation of Parts Oil Drain Line: There are many easier oil drain lines to install than the fixed length metal braid hose. We ve used them all with varying degrees of success. The only 100% correct drain line is exactly what we ve chosen here. It will require another 15 minutes to install, but regardless of whether you stop to think about it in two or three years, it will prove time well spent. The braided line also requires more care regarding placement of the hole in the oil sump or else the line will not fit, or remain in a severe bind. While mildly scary, drilling and threading a hole in the oil sump is, nevertheless, a perfectly safe process. The procedure outlined here will preclude any shavings from remaining in the sump. Should any shavings slip through and not come out when draining the oil and purging with solvent, they will find it very difficult to get off the bottom of the sump and into the oil pick-up. If any shavings still survive to enter the pick-up, they will stop in the oil filter. The turbo drain hole will lie slightly below the oil level, thus oil will run out as the drill penetrates the sump wall. The oil flow will further purge the shavings. You will actually see them flowing out in the oil. The drain hole location is on the left (driver) side of the oil sump, just below the A/C compressor. If your Miata does not have an A/C compressor present, move the drill location up about 1" and forward 1/4". Locate the position of the drain hole. Mark a point 2.3" below the lower lip of the oil pan flange that bolts up to the engine block. With a straight edge across the front of the oil pan, approximately 2" below the pan flange, measure aft 1.5" and mark the spot. So, 2.3" down and 1.5" aft is the place to drill for oil.(just don t expect to get rich off of this discovery.) Place an oil drain pan below the sump. Refer to picture # 1. Copyright BEGi

5 Picture # 1 With AC lines and other paraphernalia in the way of where the hand drill needs to be, it is almost impossible to drill the hole perpendicular to the sump wall. This does not matter, as long as the tap is held straight when cutting the threads. Just hold the drill as straight as possible and the tap can fix the real thread direction. Drill the hole with the 0.312" diameter drill bit. Grease the end of the bit to collect the shavings as the bit is about to penetrate the wall. With this as a pilot hole now drill with the.578" bit. Use the same greasing procedure as above. Try not to let the drill bit suck itself into the sum when the wall is pierced. Tap the threads with the 3/8 NPT tap. The tap can best be driven with a ratchet wrench. Use an 8" to 10" extension and a 16mm or 5/8 twelve point socket. Grease the tap to collect the shavings. Again, you will see the shavings coming out with the dripping oil. Make every effort to hold the tap horizontal. The oil drain function will not be compromised if it is at a slight angle, but it sure will look sloppy. Stop every two threads, remove, clean and re-grease the tap. Sink the tap until two or three threads on the tap remain outside the wall of the sump. Let the oil drip for a while, then clean the surfaces as thoroughly as possible. Spray some solvent on the threads. Install the AN816-08D fitting into the sump. Use a smudge of Permatex to seal. Refer to picture # 2. Add the drain line onto the fitting and route the hose upward. Finger tighten only. Refer to picture # 3 & 4. Drain the engine oil. With the aid of a funnel, pour one quart of mineral spirits through the hose to purge any shavings that fell into the sump. Allow the solvent to drain for approximately 30 minutes before replacing the sump plug. Tighten the sump plug right now. Check the sump plug for security. Losing a sump plug would be memorable. Remove the oil drain line from the fitting at the sump. Picture # 2 Copyright BEGi

6 Picture # 4 Picture # 3 Preparing the Turbo: Several assembly steps can be more easily done with the turbo prior to installation. In handling the turbo, please exercise care as they are VERY sensitive to dropping and foreign particle damage. Check the turbo for any foreign particles inside. Clean the gasket surfaces. Cover the compressor inlet and outlet with sandwich bags and a rubber band to avoid junk getting into the turbo. Note: Some debris is damaging, some is harmless. Oily smudges mean nothing. Aluminum shavings burn up in the combustion and are harmless. Anything reeking of iron or silicon (glass beads) is a killer and can ruin a cylinder in a heartbeat. ANYTHING hanging around the turbo oil inlet can prove harmful. Rather than trying to decide what s what... The drain hardware is composed of the gasket, two cap screws, the aluminum drain plate and the big hose barb (or AN fitting). Place the drain plate in a vice for convenience of tightening the hose barb. The plate is tapped to 3/8 NPT in the center and the hole in one side is bigger than the other. Place the bigger side up. Put a drop of Permatex on the barbs threads and crank it into the drain plate. It should screw into the plate until only two or three threads remain exposed on the barb. Make it snug. Run a thin bead of Permatex around the center hole of the plate to seal to the gasket. Place the gasket onto the plate and add the same bead of sealant to the surface that will mate with the turbo. Secure the drain plate assembly to the turbo with the two cap screws. These tighten with an allen wrench. Crank em down pretty snug. Refer to picture # 5 & 6. Copyright BEGi

7 Picture # 5 Picture # 6 Attach the oil drain hose to the drain fitting on the turbo. Attach the water line to the turbo. It will attach to the water fitting that is closest to the four bolt flange. Tighten the hose assemblies now, as it is very difficult to reach them once they are installed. Caution: these stainless steel braid lines will chaff completely through brake lines, hoses, and body metal. Insure that the steel braided lines are not allowed to rub on anything that would not be damage tolerant. It is best that they do not rub on anything. Reinstall turbo. Run the oil drain line to the oil pan and secure. Check the sump plug for security. Losing a an oil line would be memorable. PLEASE REVIEW THE INSTALLATION AS ACCOMPLISHED THUS FAR. WHEN SATISFIED THAT ALL ITEMS ARE IN PROPER ORDER, PROCEED TO THE NEXT STEP. Testing Procedures Start the engine and check for oil leaks. Correct as required. 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. Copyright BEGi

8 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. Engine oil change interval for mineral base oils is 2500 miles. Synthetic base oils may extend the interval to 5000 miles. The synthetic oils are strongly recommended. 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 cannot guarantee fitment of the downpipe with aftermarket exhaust systems. 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. 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 turbo kits will pass smog tests. For California residents, some BEGI kits 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 will not pay your speeding tickets. Copyright BEGi