Mazdaspeed 6 Power Steering Cooler Kit Install Guide 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 Phillips and flathead screwdrivers Pliers Drain pan Socket wrench: 8mm 10mm 11mm 12mm 21mm or wheel lug socket Extenstion Fluid required: 1 US qt ATF M III, M V or equivalent (e.g. Dexron III) The bumper does not need to be removed in order to install the cooler. However, removing the bumper allows for much more access to install the cooler. Refer to the bumper-removal guide. 2
Begin by lifting up the front end of the vehicle, and properly supporting the vehicle on stands or a lift. Remove the undertray splash-guard(7 X 10mm) Partially remove the driver s side fender-guard, and left fender-guard hang(4 X 8mm) and screw clips(2 X Phillips) 3
Remove the driver s side wheel(5 X 21mm or wheel lug socket) Remove air box resonator, if equipped(3 X 12mm nuts extension required) 4
Remove inner splash-guard(6 X Phillips screw clips) 5
Using pliers, slide the 4 spring loaded clips off the factory PS hoses 6
Unbolt the factory cooler/hard line from the subframe(2 X 10mm) 7
With drain pan ready, remove the factory cooler/hard line from the small PS hose, connected to the front hard line, 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) Remove the S shaped rubber hose from the PS rack that is attached to the hard line 8
Remove the factory hard line from the vehicle, and tilt the line to allow fluid to drain. Once the fluid has drained from the line, remove the bracket from the line, and the rubber grommet from the bracket 9
Remove and clean the S shaped rubber hose on the hard line, as it will be reused If your hose is damaged, leaking, or rotting, replace it. The Mazda Part Number is: GJ6A32684A 10
Remove the short PS rubber hose from the front hard line, and install the S shaped hose onto the front hard line, and slide 2 new hose clamps over the line: 11
Mazdaspeed 6 Power Steering Cooler Kit Install Guide Mount the new Damond Motorsports cooler to the brackets as shown: 12
Mazdaspeed 6 Power Steering Cooler Kit Install Guide 13
Mount the DM cooler and bracket to the subframe, with the supplied bolt and washer, and install the S shaped hose into the top port of the cooler: 14
Take the bracket removed from the oil cooler/hard line, remove the rubber grommet, and place in on the new hose as such: Install the new hose onto the PS rack, and secure it with a provided hose clamp 15
Route the hose to the front of the car, and mount the re-used bracket as shown: 16
Route the hose to the front of the car, along the inner side for the subframe, and secure the hose to the subframe with the provided zip ties. 17
With the hose routed to the cooler, test-fit the hose and cut it, so there is a bit of slack and no sharp bends, and install the hose to the lower port of the cooler 18
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). Reinstall the inner splash guard, under splash guard, fender guard, and driver s side wheel(and front bumper if removed) 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. 19
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. The cooler should provide around 15-20% cooler temperatures, however you can modify your fog light shroud and bumper to provide forward air flow to the cooler. The smaller cooler we tested showed 25% cooler temps with the shroud and bumper modified. If you wish to order a spare shroud to do this on, the part number is GP9A50C21C You ll first want to remove the fog light shroud, by pushing in the plastic retaining clips that hold it in. 3 are shown here, there are 5 in total: 20
With the shroud off, determine the holes you want, and use the mesh as a guide, for a factory look. With a very small drill bit, from the front of the shroud, drill in each corner of the parallelograms in the mesh, of the holes you want to create. Once the drilled holes are created, take a dremel with a cutoff wheel, and flip the shroud over to the back, and cut between the drilled holes. Clean up the cuts with a knife, and sandpaper or file. Next you ll need to cut into the bumper. Test fit the newly modified shroud to see where you ll need to cut. Trace the area that will be cut(try and keep the spots where the shroud clips into the bumper). Use a dremel and carefully cut the plastic along your guide. Here s a couple pictures of the finished product: 21
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