Mazdaspeed 3 Power Steering Cooler Kit Install Guide Copyright DD2, Inc. 1
WARNING: By installing this Product, you understand that: The buyer/user assumes all risk as to quality, performance and use of these products and agrees to hold DD2, Inc. DBA Damond Motorsports ( DM ) and its representatives not responsible for any injury, loss, or damage; including any and all incidental or consequential damages arising from the sale, installation, or use of our products. Many parts are intended for OFF ROAD and RACING applications only. It is suggested that State and Federal emission regulation be checked, to see whether or not this product complies with those laws. Read through the instruction guide thoroughly, before attempting this install. Do not install any components while the engine is running or shortly after the car has been running. Give the car some time to cool down. Failure to install this product correctly, or failure to remove/reinstall existing components correctly, could result in poor running conditions, or even component and engine failure, which the sole user of this product is responsible for. The install instructions are intended to guide you on how to install this product properly. Only an experienced mechanic should perform this install. In addition, DM, and its representatives reserve the right to modify and or discontinue parts without notice. If you the user/buyer of this product do not agree with the above, contact DM immediately, to discuss a possible return of our product for a full refund minus shipping costs, and other fees. Tools required: Jack with jackstands, or lift(not necessary) Phillips and flathead screwdrivers Pliers Drain pan Socket wrench: 8mm 10mm Extenstions Fluid required: 1 US qt ATF M III, M V or equivalent (e.g. Dexron III) This can be done without lifting the front of the car. However there may be more access by lifting up the front end of the vehicle, and properly supporting the vehicle on stands or a lift. Copyright DD2, Inc. 2
Remove the bumper, with reference to the shop manual, here are the clips and clip locations for removing the bumper: These are Phillips head screw clips, twist the screw portion and pull up on the clip to remove it. Remove the air guides once the clips have been removed. Copyright DD2, Inc. 3
Clips 1 are Phillips head screw clips, twist the screw portion and pull up on the clip to remove it. Clips 2 and 3 can be removed with either a Phillips head screw driver, or an 8mm socket. Clips 4 are a standard Phillips head style screw Remove clips 5 by prying up the inner portion of the clip with a flat head screw driver Partially remove the driver s side fender-guard, and left fender-guard hang(4 X 8mm) and screw clips(2 X Phillips) Copyright DD2, Inc. 4
Once all clips and screws have been removed, pull on the sides of the bumper where it meets the fender directly outward from the car, as indicated in the arrows in the picture above. The tabs in the center of the bumper can be unlatched by pulling up. With the bumper slightly off of the vehicle, unclip the ambient temp sensor from the harness, as well as the fog light harness from the bulb connectors With all clips, tabs and wires unattached from the bumper, remove the bumper from the vehicle, and set aside. Copyright DD2, Inc. 5
Remove the both side air guides from the front of the vehicle, if equipped(10mm): Copyright DD2, Inc. 6
Next unbolt the factory cooler from radiator shroud: Copyright DD2, Inc. 7
Mazdaspeed 3 Power Steering Cooler Kit Install Guide With drain pan ready, remove the factory cooler/hard line from the rubber PS hoses(the factory clamps will be reused), and let the fluid drain into the drain pan(to push more fluid out of the system, turn the key to the ON position and turn the steering wheel back and forth(caution: DO NOT START THE CAR, THE POWER STEERING PUMP WILL RUN DRY AND GET DAMAGED) Insert the provided barb fittings into the factory hoses, and place the factory clamps onto the hose(there will be a slight indentation in the hoses, match the grove/indentation with the hose clamps). Copyright DD2, Inc. 8
Mazdaspeed 3 Power Steering Cooler Kit Install Guide Install the new hose and provided clamps onto the barbs Tighten the provided hose clamps on the hoses, so the clamps are roughly ¼ behind the raised ports of the cooler and hard line(do NOT OVER TIGHTEN THE CLAPS, AS THE HOSES MAY TEAR). Copyright DD2, Inc. 9
Mount the cooler using the provided hardware as shown, to the bracket and bumper/hood latch support bracket. Route the hoses as shown, the hose that attaches to the higher port on the cooler will attach to the feed hose, or lower of the two factory hoses. Copyright DD2, Inc. 10
Mazdaspeed 3 Power Steering Cooler Kit Install Guide Copyright DD2, Inc. 11
Reinstall the bumper following the reverse of the removal procedure. Fluid Fill and Bleeding Procedure: 1. Take your new fluid and add it to the steering fluid reservoir, until it reached the FULL marking. 2. Turn the key to the ON position and turn the steering wheel fully back and forth(do NOT START THE CAR YET). 3. Re-inspect the fluid level. If the fluid level has gone down, add fluid to the full line. 4. Repeat steps 1 & 2 until the fluid level stabilizes, there are no bubbles coming up, and the fluid level no longer goes down. 5. Check for leaks along the new cooler and hoses. 6. Lower the vehicle, check fluid level. 7. Start the engine and let it idle, check fluid level, check for leaks along the new cooler and hoses(if there is a leak or the pump screeches loudly, turn off the car immediately, and fix leak/add fluid). 8. Turn the steering wheel fully back and forth several times(cation: DO NOT HOLD THE WHEEL AT FULL LOCK IN EITHER DIRECTION FOR MORE THAN 2 SECONDS). 9. With the steering wheel straight, car idling, check that the fluid is not foamy and the level has not gone down. If the fluid level has gone down, add fluid to the full line, and repeat Steps 8 & 9. 10. Put on the reservoir cap, and check again for leaks. Copyright DD2, Inc. 12