The BEGi 1.8L Mazda Miata Exhaust Manifold. Installation and operations manual Applicable to all 1994 to liter mazda miata

Transcription

1 The BEGi 1.8L Mazda Miata Exhaust Manifold Installation and operations manual Applicable to all 1994 to liter mazda miata Revised Rev 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 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 Floor Jack & Jack stands x 4 General SAE open/box wrenches Assorted slot and phillips screw drivers General metric socket set Hand drill and assorted bits Factory shop manual or equivalent is recommended Spray Solvent - 1 can Wire brush Clean rags WD-40 Spray or Similar 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, clamps and turbo hose. They will be re-used. If your car is stock, remove the 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 applicable, remove the turbo heatshield, EGR fitting off of the manifold, turbo, exhaust manifold, and downpipe. You will also need to remove the compressor inlet and outlet tube. It may be possible to remove the turbo and set to the side, gently, without removing the oil and water lines to the turbo. Be sure to cover all openings in the turbo with plastic bag and rubber band so that nothing can fall inside and destroy your turbo. Installation of Parts Exhaust Manifold: Bag # Inspect the inside of the exhaust manifold for debris. Clean as necessary. Refer to picture # 1. 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 # 2. Picture # 1 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. Note: Tighten the stud in the manifold about half that with which you would tighten the nut alone. This pre-load is actually what gives the stud its magic fastening characteristics. Install the EGR fitting (2353WE), adapter as shown. Point the fitting between directly aft and very slightly inboard. Take a look at the EGR tube on the car and see if it is truly parallel to the head, or other. The ferrule installs later as the EGR tube is engaged. Refer to picture # 3. Picture # 2 Turbocharger, Downpipe & Manifold Installation: Bag # These three items must be installed in this sequence: 1. Lay the downpipe in place and engage the studs at the front of the cat. Add nuts, but leave them loose. 2. Install the exhaust manifold. 3. Install the turbo. Picture # 3 3

4 Picture # 4 Picture # 5 Place the exhaust manifold onto the head. Refer to picture # 4. Reuse the original manifold to head gasket. These are stainless, virtually indestructible and entirely re-useable. Clean it up a bit with solvent or a brillo pad, if needed. Bolting up the manifold can be a bit dicey. The EGR tube nut is quite ornery to engage unless the manifold is free to move around. The center nut can only be started with the manifold still pulled away from the head. o Place the small ferrule (29214) into the 90 EGR fitting beneath the manifold. Refer to picture # 5. Attach the EGR tube to the fitting. Give it two or three turns to be sure its not cross threaded. Wait until the manifold is tight against the head to finally tighten the EGR tube. It will probably be necessary to pry the EGR tube aft about.30 inch in order to engage. Snug up all the manifold to head fasteners. Now tighten the EGR tube. Refer to picture # 6. Place the turbo in position. Add the original fasteners, and leave them all loose. With minor manufacturing tolerances, it is sometimes too tight between the manifold studs and the frame lip to slip the turbo onto the studs. If this occurs, remove the lower front stud, place the turbo onto the three studs, then replace the fourth stud. Refer to picture # 7. Picture # 6 Picture # 7 Slip the downpipe onto the turbo. Re-use original fasteners. Do not tighten anything yet. Refer to picture # 8. Now, tightening fasteners MUST be done in the following sequence. If the sequence is not followed, the convertor will wind up touching the bottom of the car. Refer to picture # 4, 7 & Turbo to Downpipe 2. 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 Picture # 8 4

5 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 91 octane or higher 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. 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. 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