Rang-a-stang's GenWon

[rang-a-stang]

I am not sure I can really call this a "build" as much as I would call it a diary.
Current configuration:
2009 GT. Here's my introduction thread:
https://mazdaspeeds.org/index.php?threads/hello-mazdaspeed-bretheren.10652/
I also have most of my parts listed in my signature. My wife actually bought me this car, new in 2009 as a celebration of us fighting through marriage problems and succeeding. I will never sell this car!!

Problem Statement:
Went on a road trip with my 16yo son and this happened:
https://mazdaspeeds.org/index.php?threads/did-my-turbo-just-puke.10653/#post-80315

So I asked a bunch of questions here:
https://mazdaspeeds.org/index.php?threads/should-i-replace-or-rebuild-my-turbo.10674/#post-80165
and here:
https://mazdaspeeds.org/index.php?threads/how-do-i-pick-a-tuner.10724/#post-80311

Then ordered a BNR S3 and it's related goodies.

Cleaned my valves; they were not as bad as they have been. Here's when I started.

I use gasoline to soak the gook. Usually, I just drop about 1/8-1/4 cup of gas down there, let it sit for about 10 mins, scrape around with a long pick I have, let it soak another 10 mins, then pull the gas out with a paper towel.

Then I take the old walnut shells to the valves trick. I tried using a vacuum the first time I cleaned my valves and found it does not prevent as much of the mess as it should and I felt like it slowed the walnut shells making them less effective at removing the goop. So now I just make a tent and tape off the area like a dentist and blast away. It cleans the valves super efficiently and I use hardly any shells. Cleanup is not so bad because they all land on the sheets or the floor at my feet.

Of course, I made sure I wouldn't catch the 'Rona while blasting because I had on my N95 mask.

Cleaned everything up but didn't really put anything back together while I wait on my Turbo and it's pals. Notice my car is still filthy from the road trip where my turbo died. Poor dude!

This bracket has been broken on my engine for a long time. Probably at least 8 years. There is a dude in LA that parts MS3's out and he says he has one. I could weld the stocker back together but my welding skills are almost as good as my modeling skills (NOT good). Do these break a lot? It's the bracket on the HPFP that holds alot of the engine harness and vacuum lines. The turbo inlet also hangs on it.

I also mangled the heat shield/blanket thing that hangs on the firewall when I was pulling my Turd-bo out. This was before I wrestled it out. It's much worse now. I will order a new one.

All my parts are spread out in the garage. Looking forward to the new ones getting here (hopefully) later this week.

I just sent $$$$$ To Freektune today. Tomorrow I have to order some little odds and ends (gaskets, etc.) in prep for my new S3. I also plan to clean out my intake manifold and EGR valve while I wait. I am pretty tapped out financially at this point. I need a CC but don't have the cash. When I reinstall my intake I am going to run a line from the PCV to the driver side frame horn, then back to the intake. That way when I do have some cash (hopefully the end of the summer), I can just order a CC, cut that line at the frame horn, and install it without having to mess with the PCV system.

Any advice? I am more of an AMC/Jeep guy so even though I have had this car for close to 12 years, I consider my self an MS3 NEWB. I know my stock TMIC and Downpipe are going to choke my S3 but I am OK with that for now. I will watch Craigslist/FB Marketplace to see if I can find used ones later and get them installed when I can.

 

[Raider]

So far, so good! I have not seen that bracket break before, but shit happens. For the OCC, I used a 5/8" brass barbed fitting to connect the hose from the IM to the OCC stuff. Did not touch the PCV valve then.

 

[Duey1083]

That is quite the setup to clean your intake valves! I've had it done once before, but never tried it myself. Looks like it makes a pretty big mess in the garage.

Were you able to remove the k04 through the top of the engine without removing the exhaust manifold? How were the heat shield bolts and DP-to-turbo and turbo-to-EM studs and nuts on your car? I used a heavy hitter impact when I did my test pipe...theres NO way I could have done that job without it.

I ordered a Damond catch can three years ago and I've just been sitting on it. Living in Canada I am fearful of having the can freeze up on me. This fear is not without merit as my 2003 BMW 330i (such a POS) that I had before the MS3 had an air-oil separator that came stock and it froze up, causing my crank case pressures to spike and ended up blowing my valve cover gasket and causing a total of $1800 damage.

Anyways, I may post it in the for sale section soon. You would need to donate to use that section.

 

[rang-a-stang]

So far, so good! I have not seen that bracket break before, but shit happens. For the OCC, I used a 5/8" brass barbed fitting to connect the hose from the IM to the OCC stuff. Did not touch the PCV valve then.

Ok, that makes me feel better about buying a factory one (broken bracket).

Maybe I don't understand how the CC is supposed to hook up, then. I though the CC was placed between the output of the PCV valve and the nipple on the IM? I was just basically going to make a really long hose there and when I did get a CC, I was going to stick it in that line.

That is quite the setup to clean your intake valves! I've had it done once before, but never tried it myself. Looks like it makes a pretty big mess in the garage.

Were you able to remove the k04 through the top of the engine without removing the exhaust manifold? How were the heat shield bolts and DP-to-turbo and turbo-to-EM studs and nuts on your car? I used a heavy hitter impact when I did my test pipe...theres NO way I could have done that job without it.

I ordered a Damond catch can three years ago and I've just been sitting on it. Living in Canada I am fearful of having the can freeze up on me. This fear is not without merit as my 2003 BMW 330i (such a POS) that I had before the MS3 had an air-oil separator that came stock and it froze up, causing my crank case pressures to spike and ended up blowing my valve cover gasket and causing a total of $1800 damage.

Anyways, I may post it in the for sale section soon. You would need to donate to use that section.

Yeah, it makes a mess if I do not do a good job tenting the front when I clean my valves. BUT it costs almost nothing except time at this point. I bought the JBR IM gasket (reusable) and the box of walnut shells has cleaned my valves 4 times and I am not even half way through it. This time though, Set up (tenting) took about 15 mins and cleanup took about 30 mins.

Yeah, my K04 came out the turbo inlet side. I removed my EGR Valve since it needed cleaning anyway, then with everything else removed along with some cussing, it came out without damaging anything. I also removed the lower bracket (the bracket with one stupidly tight bolt into the turbo and 2 into the block). 3 of the 4 studs came with the nuts when removing the turbo from the exhaust manifold. That helped ALOT getting it out.
THOSE NUTS!! (both DP and Manifold) I have a Snap-on impact wrench and they laughed at it! I have a 36" breaker bar and even then I had to lean into them pretty good. All 5 of the DP studs came out with the nuts. That also helped.

Copy that. I may have to donate to get into the classifieds. I love buying stuff like that!

Holy overpriced!!! That stupid heat shield thing I mangled is $40 plus shipping!!! Oh, it's not a heat shield according to Mazda; It's a bracket (part number BA6R-61-472A).

 

[Awafrican]

You're correct typically the first OCC connects between then IM and PCV valve, as the OCC come with hoses personally I wouldn't worry about buying hose to cut and place. You can get it on just fine with the intake manifold on.

Pic from Damond

 

[Duey1083]

I haven't yet fully decided on what I want to do with the OCC yet. I need to talk to some fellow Canadians (@Awafrican) on these boards to find out if they've had issues running them. Im just a bit hesitant with it because I know the damage they can also cause if they go wrong. I know it's a beneficial mod...so I may still opt to run it. But I dont think it keeps the valves perfectly clean if you're still running the EGR valve anyways.

@rang-a-stang, I'm gonna message you to find out more details on your setup for cleaning the valves. I think I'd like to try and tackle it myself next time and save $1000 (CDN).

 

[Awafrican]

@Duey1083 I'm out in Manitoba so I see -35c here in the winter or lower. I've only been here since Jan but did see those temps. I daily the car I got the damond OCC and I've been running it in their "stage 1" config and it's been great. Had it in south east Ontario for 2 maybe 3 years prior to that.

As for valve cleaning CS actually has a good guide and their tool works well

https://mazdaspeeds.org/index.php?threads/valve-cleaning-how-to-do-it-and-why.5969/

 

[rang-a-stang]

Ok, that's what I thought @Awafrican.
@Duey1083 that write up that @Awafrican posted pretty much how I do my valves except I do not use a vacuum. I just make a huge tent to work in.
**************************************
Started cleaning parts while waiting for parts. Noticed my turbo inlet has been rubbing against the side of the computer. It wore into the metal. I assume this is because of the broken bracket.

I gave it a good cleaning, hit it with some 220 grit and re-painted it flat black. The more hidden it is, the more stock looking I can make it, the less chance I have a CA smog nazi will find it.

Just got an email from RPM. I guess the Grimmspeed EBCS and MAP are both backordered. Stupid COVID.

 

[rang-a-stang]

I'm officially over budget but not by much and I think I am covered. Spark plugs were an unexpected $40, spending $50 and the local Mazda dealer for some gaskets and that stupid heat blanket thing. The tune cost was $45 more than I budgeted too. EBCS and MAP Sensor are both back ordered. I talked to Grimmspeed today and they said they are building their EBCSs right now and hope to ship out soon (like in a week or two). I am OK waiting for them since my work just told us we are home for another month. (I work for the Navy; not IN the Navy but for the Navy).

In the mean time I am prepping/cleaning (really just wasting time until parts get here). About 2 years ago I was assembling a home made EFI for another vehicle and I bought this electrical degreaser spray and a cool electronic component store here in Camarillo to clean electrical parts and connectors I pulled from the wrecking yard. I cleaned everything by hand so this degreaser has been sitting on my self since. Tonight I pulled it out and decided to try it on some connectors under my hood. THIS STUFF IS AMAZING!!!

A couple quick spurts and that connector and its wires looked awesome. I had to find another greasy connector to clean for pictures. I found the fuel pressure sensor (I assume that is what this is) looked a bit dirty:

2 super quick psh.. psh..

I cleaned out my intake manifold with brake cleaner, cleaned out the EGR Valve, EGR Tube, and that's about all I can do until parts start showing up. Oh, I got my first MAP from Justin at Freektune. I put it on my AP but with no battery (or computer) I can't flash my computer yet.

 

[Duey1083]

Looks like things are coming along well!

Have you done a lot of work on cars or mechanical things before?

I always tend to stress myself out before tackling a job on my car...I think I've psyched myself out of doing the downpipe unless I absolutely need to. Right now I think I've resolved to wait to do the downpipe until I do the turbo. That'll be a pricey day, haha.

 

[Awafrican]

Sounds like you're off to the races and ready to put everything in once you get parts which is awesome. Are they going to split shipment so you can get the turbo installed less ebcs and map sensor? Glad you've already got the basemap from freektune, I'm excited for you to see the difference between his tunes and the stock one yes more power but drivability is improved too.

 

[rang-a-stang]

Looks like things are coming along well!

Have you done a lot of work on cars or mechanical things before?

I always tend to stress myself out before tackling a job on my car...I think I've psyched myself out of doing the downpipe unless I absolutely need to. Right now I think I've resolved to wait to do the downpipe until I do the turbo. That'll be a pricey day, haha.

Meh. Not much going on, just waiting for parts.
Yeah, I started in air cooled VWs in the mid 90's and have never given up. I have had muscle cars, sand trucks, a cool early 70's Dodge van, etc. My current project is a '79 Jeep Cherokee Chief. I built the engine and hobbled the fuel injection together from a bunch of mid 90's GM vehicles.

Having an "extra" car takes a lot of the stress away. I have time to research and wait for the right parts. If I get stuck/frustrated during a job, I can stop and take a break, regroup, research, then get back to it. It does suck daily driving my Jeep because the A/C and cruise control do not work. Oh, and it has about the same HP as my MS3 but an extra 1700 pounds, and has half the gears. Another stress relieving tip: I always budget for tool(s) in pretty much any job. Even if it is just spark plugs, it is important to have the correct tools. That takes a lot of stress out of jobs, too.

Sounds like you're off to the races and ready to put everything in once you get parts which is awesome. Are they going to split shipment so you can get the turbo installed less ebcs and map sensor? Glad you've already got the basemap from freektune, I'm excited for you to see the difference between his tunes and the stock one yes more power but drivability is improved too.

Yep. More on the split shipment below. Me toooo!!! (excited!!!!) This is gonna be awesome! God willing!!! LOL!!
*************************************************
So not a lot going on these days. Just waiting for parts. Here's what I have so far.

Stupid heat blanket, EGR gasket, oil drain tube gasket, MAP Sensor harness, TB gasket, Spark Plugs, 2.5" to 2.35" coupler, and coolant. You'll notice I do not have yet: Turbo, Boost tubes, MAP Sensor, and boost controller. GGGrrrr...... RPM said BNR built my turbo this week and was going to ship it today. I hope so! I am dying to see it! I am going to make a lamp out of my K04. Would look good on my desk at work.
I mentioned earlier about my welding skills suckin. Well, my "in" with the dude that parts out MS3's in LA fell through and I did not have access to a replacement for that broken bracket so I decided I would try to weld it up. If I mess it up, I need a new one anyway, right? Whelp, here's my pet caterpillar. It's ugly but it's strong enough to hold the wires and vacuum lines! I hit it with some aluminum color spray paint so it won't rust. You are welcome to laugh at it all you want, I won't be offended.

I also noticed this: on 3 of the factory Mazda part labels they have these random pictures printed on them. Not sure what they mean? Why a dude jumping a dirt bike?! The third part is not pictured but it had a 2 headed looking eagle... Weird.

 

[speed31982]

Love the progress, and it is very similar to my project starting in March. Some things I ran into that might help you. Did you send your injectors to get cleaned? I was a few interations into tuning when we had target AFR issues, see the before and after for my injectors. Got up to 23 psi on my BNR S3 with AFR at 11.3, and now on to my next issue. I am working with Will at Purple Drank, and we seem to have a flow problem that we think is my Treadstone TR6. Running stock exhaust manifold, and stock intake manifold has a mild port along with a port and polish on my head. I am running the JBR underside piping, so wondering what FMIC and piping you went with. I am going to try getting myself a TR8, so we can continue tuning.
Good luck and can't wait to see what you think of the car once you get into some boost!

Sent from my SM-N975U using Tapatalk

 

[rang-a-stang]

Good info @speed31982, thanks for posting up! I did not have my injectors cleaned. I usually run a can of Techron fuel injector cleaner through my tank at each oil change so I assume(d) they are clean'ish. How much was injector cleaning? How long did it take? Who did you send them to?

HAHAHA! I still have a stock TMIC. Stock intake manifold. Stock exhaust manifold. Stock Down pipe!!! LOL! I know my S3 will not achieve anything close to what it is capable of right now but I am OK with that. Over the next couple years I will pick up a downpipe and either a FMIC or TMIC but I have done no research into those right now. Just tryna get my car back on the road.

Boost tubes showed up yesterday, shipping confirmation on turbo says it will get here Friday. Car is sitting.

 

[speed31982]

No problem, and you wouldn't of even known I had an injector issue until the tuner realized we were about 20% off. I have an 07 with 125k miles and the engine was rebuilt at 75k. I sent them to overspeed motorsports, which I would also recommend their injector seals also. I got it to them just before the covid-19 started, so it was a quick 3 day turn around on the injectors and was $100 + (I can't remember the exact price). I started getting a bunch of knock as soon as tuning started also, which ended up being the injector seals.

 

[Awafrican]

+1 for overspeed seals, I know they do cleaning too, pretty sure Injector Rx is the main place that gets recommended for cleaning
Edit: did further checking confirmed injector Rx is the most recommended place for cleaning

 

[rang-a-stang]

Understood, @speed31982 and @Awafrican . I will keep that in mind. I really hope mine are not toast cuz that would be another about $140 and pulling the intake again. I hope the next $140 I have to spend on my MS3 will go to a CC.
***********************************
I was all excited because my Turbo was supposed to show up today but FEDEX sent me a notice and said it was delayed. Now not until Monday. Grrrrr...

I did get my MAP Sensor (was back ordered) so I started putting the front of the engine back together. I thought it was cool that the OEM MAP sensor was also a Bosch (judging by the emblem on the top), said FoMoCo on it and had made in Germany.

Stuck it on my Mani and stuck my adapter on. I spent a couple minutes trying to figure out the best way to route the extra length of wiring where it would not rub on anything, collect dust, or get too hot.

This adapter adds a good 8" of wiring.
Then I cleaned all the mating surfaces with break cleaner, stuck my JB Racing intake manifold gasket on (it looks like its still dirty but it's not):

Then I stuck it on my engine, replaced my spark plugs with NGKs (as recommended by Freektune) and buttoned up the front. I don't want to put the throttle body on until the EGR tube goes back on and I don't want to put the EGR tube on until the EGR valve is on and I don't want to put the EGR Valve on until my turbo is bolted in. Hopefully Monday night.

Apparently I need to clean my desk. It looks awful in these pics...

 

[Duey1083]

@rang-a-stang, great work and progress! That's a bummer about the delay on the turbo...bet you were amped up to get it installed and the car running again.

Did you replace your plugs with stock heat range?

 

[Db09ms3]

Dude! Make a build thread separate from this intro area.

Lol, nevermind. I just woke up. Carry on!

 

[rang-a-stang]

@Duey1083 I bought what Justin recommended. The closest thing I did to research on plugs was finding the best price. They are NGK 6510's
@Db09ms3 haha! WilCo!
*************************************************
Sitting/working at my kitchen table yesterday when the dog freaked out=Package at the door. Of course work is done for the day at that point. Like anyone could focus on work when a Turbo is sitting there!
I pulled it out to take a look and compare. It is noticeably larger! I expected it to be slightly larger but not this much. I am in love! I kind of feel bad for stuffing down and hiding in my engine bay. Also, check out all the Laser Cut BNR logos.

Started swapping parts and getting things put back together. There is TONS if info out there about how to do this so I am not going to give a blow by blow but here are the only "issues" I have had so far:
The threaded stud on the bottom of the turbo does not come with the BNR and you need to transfer it over. Mine was BARELY long enough to get 2 nuts on it and jamb together, to get it off. I ended up with a damaged thread and had to run a die over it to clean it up.

The heat shield that goes around the bottom interfered, ever so slightly, with the lock bolts and plates.

Nothing a set of tin snips and pliers couldn't fix.

After that, it all pretty much bolted together like I would expect. All the heat shields and bracketry fit like factory. It comes with new stainless studs for the exhaust manifold and down pipe; I was not going to use the stock nuts on those stainless studs so I went to my local hardware store and picked up some new stainless nuts. Those {badword} nuts were $2.69 EACH!!! I spent almost $30 on 9 nuts!!

One of my pet peeves is un-torqued hardware. I spent a good hour trying to figure out how to get a torque wrench on the down pipe nuts. Different combinations of deep and shallow sockets, different lengths and different types of extensions, and even 2 different types of torque wrenches and the only nut I could torque was middle top one. It's not that I could not get the wrench and socket on there'. It's that there is not enough room to deflect the torque wrench to get a good reading. The other 4 got the good ol' fashioned, "That seems about 50 foot pounds" treatment.

Last "Issue": The new coupler for my inlet interferes with a coolant pipe. I didn't spend much time on this and will figure it out later. I am not too worried about it.

So here's how it looked when I went to bed last night. I probably put about 4 hours of work in, taking my sweet time. I also killed a good 20 minutes looking for one of the #$^%^ expensive nuts when I dropped it. Car is off jack stands. Honestly, this really is "bolt on"; super easy to install. I expected at least some holes to not line up or heat shields that would need to be adjusted but just the one at the top. You'll notice all my "issues" I described above are completely minor annoyances more than anything. I am pretty psyched to get it started! Once my boost controller gets here, I will finish it up. Still back ordered....