The BEGi MazdaSpeed Miata Cool Air Intake System Installation

The BEGi MazdaSpeed Miata
Cool Air Intake System
Installation and Operations Manual
Applicable to all 2004 to 2005
MazdaSpeed Miatas
Revised 4-20-10
Version 1.3
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Thank you for purchasing the MazdaSpeed Cool Air System. 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 830-438-2890. Suggestions for improvements of these instructions are welcome. Send an e-mail to
[email protected]. Or, write notes on the instruction set and mail / fax to: BEGi, 203 Kestrel Dr.,
Spring Branch, Texas. 78070. Fax: 530-438-8361
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
Clean rags
General SAE open/box wrenches
WD-40 Spray or Similar
Torx T40/T45 Wrench and/or Socket
5mm Hex Wrench
Two Jack Stands
Floor Jack
Assorted slot and phillips screw drivers
General metric socket set
Preliminary
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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.
Place the car on jack stands and remove the driver side wheel.
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Major Items to Remove
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Save the fasteners, as many will be re-used.
Remove the stock Air intake system, Air filter box,
flow meter assembly and inlet snorkel. Keep the
rubber 90o tube handy. You will reuse it later.
Remove the flow meter connector by pinching the
tabs on top and bottom of the connector. Set the
wire bundle back by the brake master. Refer to
picture # 1.
Remove the flow meter from the filter box and set it
aside for use later.
Remove stock compressor inlet and outlet tubes and
clamps. Leave the rubber compressor inlet elbow in
place, as it will be reused. Leave the rubber Picture # 1
connecting tube on the intercooler inlet tube in place
as well.
Remove the bypass valve tubing from the stock inlet tube. This will reconnect to the new tube later
Remove the Air Temp Sensor and its rubber grommet. Set aside for use later.
Remove the bracket holding the relays. Remove the relays from the bracket and set aside.
Remove the strut tower bar. Set it back across the engine, not too far away. There is a breather tube
attached to the brace. Loosen it at the stock inlet tube, not the strut tower brace. Do not loose the hose
clamp.
Remove the “L” shaped bracket (that holds a plastic clip that attaches to the lower radiator hose).
Refer to picture # 2. This photo is from an NB Miata, but the MSM bracket is very similar.
Picture # 2
Picture # 3
Miscellaneous Duties
Securing Relays
The three relays removed from the plastic bracket just aft of the driver side headlight need to be secured out
of the way. Use a short 6mm screw and nut to anchor the two relays together. Use a zip tie to secure the third
relay to the other two. Tuck the relays in toward the inner fender just aft of the headlight wire harness clip.
There is a small body bracket just aft of the hole into the fender area that will permit a zip tie to loop around
it and the relays. Refer to picture # 3.
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Installation of Parts
Mass Air Flow Meter & Air Filter:
Place the air filter onto the mass air flow meter (thru the cool air
box) and tighten the clamp supplied with the air filter. Refer to
picture # 4. Pay close attention so that the directional air flow
arrow on the MAF is correct. The arrow should point towards the
engine.
Push the rubber grommet (that holds the air temp sensor) into the
hole on the cool air box. The sensor will then slide into the
grommet. Refer to picture # 4, 5 & 6.
Picture # 4
Picture # 5
Picture # 6
Intercooler Inlet Tube:
Loosen and remove the stock clamp on the intercooler inlet (rubber) tube. This clamp may require some
convincing to come off. The hard metal tube will be removed, along with the mounting bracket attached by
the headlight. Leave the rubber tube in place though. Place a new t-bolt clamp over the hose. Leave it loose
for now. Insert the new intercooler inlet tube into the stock rubber tube. The longer end of the tube goes into
the rubber hose. The top of the tube must run thru the frame, come upward, then point towards the engine.
Place the t-bolt clamp into position, but do not tighten it yet. Refer to Picture # 6, 7, & 8.
Picture # 7
Picture # 8
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The Cool Air Box:
Set the Cool Air Box in to position, laying it on the frame. The
air filter and MAF should be attached, but hanging loosely.
Arrange the intercooler inlet tube so that it fits thru the bottom
hole on the Cool Air Box. Refer to picture # 8 & 9. Place the
air box in position. It may be necessary to trim off an edge or
two fit around the frame of the car. If the forward part of the air
box hits the high pressure a/c line, you can bend the aluminum
to fit around it as needed.
Place the PWS reservoir into place over the Cool Air Box,
sandwiching it to the frame. Use the 6 mm x 20 mm screws to Picture # 9
fasten the Cool Air Box and PWS reservoir to the frame.
Attach the wire harness/ connectors to the mass air flow meter and the temperature sensor on the air box.
Route the wires away from any signs of trouble. Anchor with a few of the small tie wraps, if needed.
Compressor Outlet Tubes:
The Compressor Outlet tube will bolt up to the turbo flange.
Use the two 8 mm x 25 mm socket head cap screws. Secure
Tightly. Refer to picture # 10.
Attach the stock rubber, 90o elbow to the turbo outlet tube.
Secure with the #238 t-bolt clamps. Refer to picture # 7, but
remember the air box is already installed. Also, take note of the
direction of the photo. The photo was taken from standing next
to the brake booster unit looking towards the radiator.
Picture # 10
Compressor Inlet Tube:
Push the 2.75" turbo hose and size SAE 40 hose clamps onto the mass airflow meter. Leave the clamps loose
for now. Insert the smaller end of the compressor inlet tube into the turbo inlet hose. The inlet hose is located
in front of the turbo outlet flange. Refer to picture # 9 on the previous page. Insert the larger end of the
compressor inlet tube into the turbo hose on the MAF. Move clamps over to cover the inlet tube and MAF.
Line up worm gears on the hose clamps for neatness. Tighten hose clamp at the turbo inlet, then at the MAF.
Picture # 11
Picture # 12
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Replace the strut tower bar. The breather tube will run to the bung
located on the compressor inlet tube. Refer to the top left of picture
# 11. Also see picture # 12 for the line installed. Use the included
3/4" hose and stock splice to replace the bypass valve line. Refer to
the bottom left on picture #s 11 & 12. Refer to picture # 13 for the
splice. Replace the vacuum line onto the bung. If needed, a new line
in included. It is best seen in picture # 11, just to the right of the 90o
bung.
Picture # 13
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 vacuum. 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.
General Rules of Operation
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Use premium octane fuel at all times. Higher, if available.
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
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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
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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
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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.
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© Copyright BEGi 2006-2010.
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