MS3 FMIC Install - Synapse Engineering

MS3 FMIC Install - Synapse Engineering

2007 to 2009 Mazdaspeed 3 Front Mount Intercooler Pipe Kit
Removing the OE intake and battery tray:
1. Remove the top cover to explose the battery.
2. Disconnect both terminals on the battery.
3. Unclip the metal clip and unbolt the bolt as shown in
picture.
4. Loosen the 10mm hose clamp connecting the OE airbox
to the metal OE intake.
6. Remove the top airbox cover. Pinch the white clip to
remove the lock, then pull back the bracket lock
assembly.
7. Disconnect the OE breather recirculation hose and
remove the OE air box assembly.
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8. Remove the 2 wire clips in the front side of the battery
box.
9. Remove the two 10mm nut on the sides of the battery
box in order to remove the battery tie.
10. Remove the battery and the 3 x 10mm bolts from the
OE battery tray.
11. Disconnect the two ECU connectors, and then remove
the battery tray.
12. Remove the OE plastic inlet tube connected to the
turbo inlet.
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Removing the front bumper:
13. Remove the clips that are holding the left and right OE
intercooler air ducts attached to the front bumper.
14. Remove the left and right cold air channel ducts.
15. Remove the front bumper plastic philip screws on the
driver and passenger side wheel well.
16. Remove all 8mm bolts on the bottom side holding the
front bumper.
17. Unplug the clips holding the driver and passenger OE
fog lights.
18. Remove the clips attaching the fog light wire to the
front bumper.
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19. Unplug the Ambient Temperature Sensor clip on the
lower center side of the front bumper.
20. Remove the 8mm bolt holding the bumper to the
front wheel fender (Driver & Pass. Sides), and then gently
remove the front bumper.
OE Intercooler Removal:
21. Remove the two 10mm bolts holding the OE
Intercooler cover
22. Remove the two 12mm bolts attaching the OE
Intercooler to the OE Intake
23. Remove one more 12mm bolt holding the OE
intercooler on the backside
24. Remove the tube attached to the inlet of the OE
intercooler.
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25. Remove the two 10mm bolts on the front holding the
OE BPV.
26. Disconnect the vacuum hose and then remove the
BPV.
27. Remove the OE Top Mount Intercooler.
28. Remove the two 8mm bolt that holds the wire harness
bracket
29. Remove the wire harness metal bracket, then Move
the entire wire harness assembly to the left side of the
bolt.
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Installing the Front Mount Intercooler:
30. Unbolt the power steering line bracket on the
passenger side.
31. Pry loose the circular bracket clamps that are holding
the power steering line.
32. Move the bracket forward about 1 to 1.5" and then retighten the circular bracket clamps.
33. Remove the 10mm bolt to loosen the bracket on the
driver side.
34. Bend back about 30 degree on the driver side power
steering line bracket in order to gain clearance for the
FMIC.
35. Position the power steering bracket in the original
place, position the FMIC to the existing bolting locations
shown in picture and secure it with the OE bolts.
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36. Same with the driver side. Position the power steering
bracket in the original place, then secure the FMIC
brackets onto the existing locations shown in picture and
secure them with the OE bolts.
37. Check the position of the intercooler to make sure
that it is centered.
38. Remove the 12mm bolt on the OE clutch assembly
bracket.
39. Install the 2.5" straight coupler onto the driver side
(outlet) of the intercooler.
Installing the Intercooler Pipes:
40. Install the 2.5" to 2.75" reducer coupler onto the
throttle body.
41. Install the intercooler to TB pipe (KIT000025.1) onto
the IC Outlet and TB couplers, line up the pipe bracket
with the bolt hole from the OE clutch assembly bracket,
then reinstall the 12mm bolt.
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42. Install the 2.25" to 2.5" coupler onto the Inlet side
(passenger side) of the intercooler.
43. Insert the Turbo to IC pipe 2 (KIT000023.1) from the
location shown in the picture.
44. Pipe KIT000023.1 should come out to the location
shown in the picture.
45. Install the other end of pipe KIT000023.1 onto the IC
Inlet coupler.
46. Install the 2.25" straight coupler onto the turbo
discharge.
47. Install the 2.25" straight coupler onto the turbo to IC
pipe 2 (KIT000023.1).
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48. Install the Turbo to IC Pipe 1 (KIT000022.1) onto the
corresponding 2.25" couplers.
49. Line up the pipe's bracket to the bolt and reinstall the
12mm nut to secure the bracket.
50. Install the 2" to 2.5" coupler onto the turbo inlet.
51. Install the Turbo Intake pipe (KIT000021.1) onto the
turbo inlet coupler.
52. Line up the Intake pipe bracket to the bolt shown in
the picture and then reinstall the 10mm nut.
53. Reconnect the OE boost selonoid bleed hose back to
the intake's nipple.
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Installing the Synapse BOV:
54. Cut 3 appropriate lengths of the provided black PU
hose and push the pre cut hose ends into the Y connector.
55. Locate the vaccum signal line that was disconnected
form the factory bypass valve.
56. Extend the vaccum line by inserting the collector end
of the PU hose into the rubber factory line, then slide the
factory spring clamp over the inserted hose end.
57. Connect the split end PU hoses to ports A and B of the
Synchronic BOV.
58. Place the adapter o-ring in the inlet side of the BOV.
Make sure the o-ring sits flat before installing it onto the
pipe.
59. Place the BOV onto the flange and push down to seat
the o-ring. Install the two set screws or allen head bolts
provided with the BOV.
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60. Install the 1.25" x 12 " coupler onto the BOV
discharge, and connect that to the recirculation opening
on the Turbo Intake pipe. The coupler may need to be
trimmed in order to fit properly between the BOV and the
Turbo Intake pipe.
Reinstalling the OE parts:
54. Reinstall the OE battery tray components, and
reconnect the ECU harnesses.
55. Reinstall OE air box.
56. Attache the intake hose from the OE airbox to the
Turbo Intake pipe.
57. Reconnect the OE breather recirculation hoses to the
OE air box assembly.
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Modifying the OE bumper:
58. Using a Dremel or similar cutting tool, trim off both wire-harness support on the driver side bottom inside of front
bumper
59. On driver side of the bumper, trim off approximately
1" along the red line in the picture. Repeat the same
procedure on the passenger side of the bumper.
60. Uninstall the Ambient Temp. Sensor from the front
bumper.
61. Relocate the Ambient Temp. Sensor to the location
shown under the headlight.
***Optional*** Bend the Ambient Air Temp sensor
bracket into a Z shape (as shown in picture), and then
reinstall it back to the OE location on the bumper.
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62. Reinstall the front bumper and check for clearance
with the intercooler installed.
63. Reconnect both terminals on the battery.
64. Reinstall the top battery box cover.
65. Reinstall the two air ducts on top of the bumper and
reinstall all corresponding clips and bolts.
For technical support, contact Synapse Engineering Inc at +1 (858) 457-1700, or [email protected]
**The installing instructions for this product is done according to USDM 2007 to 2009 Mazdaspeed 3 vehicles.
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