Fasteddie128's BNR S3 Build

[fasteddie128]

TLDR Version at bottom because wall o text

The Plan
So when I bought my car about a year ago the turbo was smoking pretty bad. I used this to get the car at a lower price and then was able to band-aid fix the issue via Bnoon bolt, idle adjustment and thicker oil. Car had not smoked in months but it was only temporary. I originally planned on getting a rebuilt K04 or a bnr s1 but lets just say plans change. My goal was originally to stay close to stock. My goal has become to see how far I can reliably push my car while remaining close to stock appearance wise.

The Parts
This round the BNR s3, 3 bar map, 3 port ebcs, 3" intake, corksport tmic, one step colder plugs, test pipe and trz rmm were installed.

The Install
So first off huge thanks to @Mauro_Penguin; for driving up for a day and helping me get the turbo swapped out. Job turned bigger than I thought and it was nice to have the help that day. It actually took me two and a half days to get the car on the road again but if I had to do it again it would only take me a day. A lot of the time was figuring out what to do next and how to do it although I did have a few issues along the way.

Day 1 - Mauro_Penguin met me at my place. We dropped off the car at my dads garage and went to the store to grab rtv, oil and other things needed for the job. My garage is a mess so my dads was a better work space. When we got back the car had cooled and we began working. At first it all went pretty smooth. Down pipe was removed without any issues and after a few hours the K04 was ready to drop out. One thing to note is we clamped off the soft coolant lines after pulling them off the turbo's hard line's and I lost barely any coolant. Mauro removed the stock rmm and the turbo was pulled out the bottom by pushing the engine forward and rotating the turbo around the axle. The bnr went in the same way and was installed rather quickly. It really is a drop in solution, you could even use the stock intake if you bought the right turbo to tip coupling but to install a turbo like this and not upgrade the intake wouldn't make much sense.

This is where things stopped going smooth. We had issue with the test pipe. The fit was not perfect and one of the bolts seized. Got halfway in and the thread got damaged due to the pipe shifting. Whatever it could be dealt with later. Focus was shifted. Mauro got to installing the trz rmm and I torqued the nuts securing the turbo. I started installing the htp intake and Mr.Penguin had to go so I took a break and started getting a game plan together. I decide to put the battery box in and the ecu is pressed up against the intake. I was somewhat expecting this so I moved the ecu to the fuse box to velcro in place for the time being. From there I move to the pcv hose and find that the supplied hose in the bnr kit does not work with the revised valve cover. The angle the hard metal line comes out of the valve cover runs down toward the engine and leaves less than a inch to bend a line. Hose kinked every time. I would have to buy a heat bent hose in the morning. I was done for the night. Defeated I cleaned up and went to bed around 3am.

Day 2 - Got up at 7am and get my new shopping list together. Buddy stops by and drives me to napa where I find the perfect hose. Back to work I went. Started off under the car and decided to do an easy job first. Grabbed a socket wrench and started to take the stuck bolt out of the exhaust. I used PB blast earlier to try and loosen the bolt. Give the wrench a pull and it starts turning. Sweet! Then it gets harder to turn. Then really easy. Then half the bolt falls on my face. Broke the damn thing off. It seems the stock downpipe had no intention of letting my install go smooth. Ok so lets go on to something else...

I moved on to the intake and use the new hose to finish the job. Next comes the ebcs. I decide to mount it to the battery box where the ecu was for now. Time to run the vacuum lines. And I was stumped. I knew port 1 went to the intake and 2 went to the wastegate but port 3 had me stumped. Didn't know whether to run it to manifold vacuum or to the turbo compressor. I saw diagrams that showed both setups and decided to run to the turbo. Glad I did, Mauro gets back to me later that day reaffirms that running to the turbo was correct. This diagram is a good reference.

3 PORT EBCS HOOKUP ON BNRS3 V2
http://stratifiedauto.com/images/3P%...upt%20Mode.png

On to the map sensor. On gen1's you get this awesome bracket and some wiring that cover the sensor and makes the job a pain in the ass. The work area was tiny and my hands got beat to shit. I hated that damn sensor by the time I was done but whatever on to the next job. Battery goes in. Spark plugs get gapped and installed. Old plugs looked good and were uniform in color. New boost hoses get installed. Corksport tmic goes in. Things are going smooth again. Put all the little things back together and put the car back on the ground. Time to install my tune. Go to select it and turns out just renaming the file in atr didn't free it up to use on my ap. Contact my tuner and he tells me to try saving again so this time I make sure I rename and bump my idle to 900. It works and the car is ready to go.

Its 1am. Victory time. I start the car and back out of the garage. Oooohhh feels nice and sounds good. I look back in the garage and see a line of oil leading back to my car. I immediately turn the car off and get it in the air but not before getting floor dry down. The car is not going back in the garage and I am tired. I suspect its the turbos oil return line and when I look under the car sure enough the return line is covered in oil. I clean up and go to bed. Defeated again!

Day 3 - Off to work at 530am. Work a double shift then do volunteer work for the local church in the evening. Get back to my dads at 1030pm. I strap a flashlight to my head, grab my tools and its under the car I go. I clean up the mess and take the oil return off. I half expect oil in the face but the line was dry. I noticed the bolts were mixed up when I pulled a short and a long bolt out of the turbo. The short bolts go to the turbo, long ones to the block. I clean everything and check the gaskets. Both look good so i apply a very tiny film of copper rtv and re install. If you have any questions on how things go together this diagram is very helpful.

TURBO ASSEMBLY DIAGRAM
http://onlinemazdaparts.com/media/im.../5/5465152.gif

Top off the oil. Start the car. Success!!! I go around the block and return to find no leaks. Oil level good! Car is smoking like its on fire but its to be expected due to all the oil and pb blast. I go around a bit more and when everything still looks good I call it quits and clean up for the night.

Finishing Up
Still needed to finish the battery box and fix the broke off bolt in my downpipe but that was for another day. Finished up a few days later. Drilled the downpipe bolt out and put in a new one. Also modded my battery box to move the ecu closer to the battery while keeping it outside the box in its stock location. I started off marking the stock ecu mount point on the side of the battery box. I then cut a hole for the ecu to fit through while leaving mounting points for the ecu tabs. The tabs and back plate are inside the box with the ecu and plugs outside in stock location. The ebcs was moved to a tab on the engine. With it all assembled it looks very clean and I could not be happier.

Tuning
Currently having a 91 octane general use map made by the speedbakery. So far on revision 2 and the car is feeling good. Not much more hp yet but much smoother power delivery and it pulls hard all the way to the red line. I will post up some logs as tuning progresses but looking good for where its at. Boost holds steady at 15 psi currently and afr is solid around 11.6 with no knock. As soon as this map is dialed in I will be going with a corn tune. Goals are close to 310 whp on 91 and 350 whp on the corn.

TLDR Version - Installed bnr s3, bigger tmic, 3" intake, 3 port ebcs and testpipe. Ran into problems. Shit broke. Things took too long. Finally finished and tuning for the zooms.

[Mauro_Penguin]

Fucking fail on my part about mixing up the oil return line bolts. That keeps haunting me since it could have led to very bad things. I remember fighting with one of the bolts when trying to catch the threads, I must have grabbed a wrong one when it fell on me. Or maybe it was the mouth full of coolant and oil that I received earlier....

Glad it all worked out in the end! The car is such a sleeper it's stupid. Only thing that stands out is the intake.

[fasteddie128]

Originally Posted by Mauro_Penguin Fucking fail on my part about mixing up the oil return line bolts. That keeps haunting me since it could have led to very bad things. I remember fighting with one of the bolts when trying to catch the threads, I must have grabbed a wrong one when it fell on me. Or maybe it was the mouth full of coolant and oil that I received earlier.... Glad it all worked out in the end! The car is such a sleeper it's stupid. Only thing that stands out is the intake.

Mistakes???

Just kidding...

Seriously though no worries man all got sorted and I would not have been able to get the turbo in as smoothly as we did without the help. Trust me I had to do a few parts of the job over as I made a few mistakes myself. And even when done right that oil return can leak. Anyone doing a job like this needs to double and triple check for leaks.

Also you are correct sir, my car did like to try and put things in and around your mouth. But don't blame her, she just wants your body.

[HaXiR]

Your mods are pretty similar to mine. You did get a HPFP tho right? I didn't see it in the parts list

[acemanz]

yeah HPFP is basically mandatory.

[Mauro_Penguin]

Originally Posted by HaXiR Your mods are pretty similar to mine. You did get a HPFP tho right? I didn't see it in the parts list

He's been running autotech HPFP internals for a bit. It was the first gay install he had with our local Nator family.

[fasteddie128]

Originally Posted by HaXiR Your mods are pretty similar to mine. You did get a HPFP tho right? I didn't see it in the parts list

Indeed as Mauro pointed out it was the first thing I really installed. First I raised the fuel pressure, then the boost pressure. When I bought the car the tire pressure was a bit low so I raised that too...


Just started playing with map revision 3 and the car is starting to really feel faster. 50% wastegate this time.

[HaXiR]

Oh ok then, was a little worried lol

[fasteddie128]

Time for some results. Its taken a while but finally finished with tuning and have some numbers. I ended up going with freektune for my ethanol tune after seeing his work on the 10 second speed3. We started with a e25 blend but ended up going with a e33 mix. Car pulls hard and is pretty fast for having a stock downpipe and tmic.

Vdyno shows 340whp and 322wtq with cf of 1.01 and smoothing at 3. I'll include a log of the run. Boost tapers to 24ish psi. Car sucks...maf says 357 g/s. I'm happy with where the car is. Who knows it was 80 degrees out, maybe I can squeeze out another 10hp when it actually cools off.