BNR S3 Swap How To

[Navy_Mech2]

no problem man. let us know how it goes.

[TexasSpeed3]

subbed

[dantes5823]

Subbed for my future bnr build. Awesome right up man. Got any more pics of where the collant drain line you fabed up connects to?

[silvapain]

Originally Posted by Domino81 I learn SO much more and SO much easier with visual aid. I can gernally do anything if I've seen it done once.

Is that how you learned to masturbate?


Tapadatass

[Domino81]

No. That came naturally.

[Ziggo]

Originally Posted by dantes5823 Subbed for my future bnr build. Awesome right up man. Got any more pics of where the collant drain line you fabed up connects to?

In 3.5.2 there is a pic of its routing. If you follow the braided hose you can see where it plugs into the EGR.

[dantes5823]

@Ziggo, any recent vd plots? updates? Im starting to peace my parts up and just wanna make sure im going the correct route.

[Ziggo]

I don't have any VD plots since I worked the tune on the drag strip a few weeks ago. I have a few more pieces to install and then I am going to dyno it.

The additional "power" parts are a high pressure relief valve and injector seals. Also going to clean my intake valves while I have it open (45k miles with no catch can or EGR blockoff)


Zigatapatalka

[dantes5823]

Originally Posted by Ziggo I don't have any VD plots since I worked the tune on the drag strip a few weeks ago. I have a few more pieces to install and then I am going to dyno it. The additional "power" parts are a high pressure relief valve and injector seals. Also going to clean my intake valves while I have it open (45k miles with no catch can or EGR blockoff) Zigatapatalka

Ouch...might wanna pull off the mani and let it drain lol. I saw my valves after 10k miles and having both things on for about the last 3k and i was disappointed. AND i run meth -__- . But im curious on your gains. Ill prob beat ya to it tho lol.

[Boosted Beluga]

Originally Posted by Ziggo I don't have any VD plots since I worked the tune on the drag strip a few weeks ago. I have a few more pieces to install and then I am going to dyno it. The additional "power" parts are a high pressure relief valve and injector seals. Also going to clean my intake valves while I have it open (45k miles with no catch can or EGR blockoff) Zigatapatalka

Any updates?

[Ziggo]

Originally Posted by Boosten Ya(josh) Any updates?

This weekend is EGR, injector seals & studs and intake valve cleaning. Thermal gaskets and port the intake manifold if I am feeling frisky. Decided to hold off on the HPRV till we have better ECU controls.

[Boosted Beluga]

Nice. Looking forward to see the results.

[ms6forthewin]

I think someone should put this in the how to date-base

This is some good shit, helped me install my s3

[Boosted Beluga]

Nice keep us posted. And post pics if you have time to take any.

[Ziggo]

Since there have been questions regarding the Coolant line routing I snapped an extra picture.

[Ziggo]

Valves were in various states of disarray. Left valve of driver side cylinder was the worst:



Right Valve of Middle passenger side cylinder was the best, with just some gunk on the stem:



No evidence of injector seal leaks.

[Ziggo]

Whoops..

Be careful reinstalling your fuel rail

[himurax13]

Subbed for awesomeness.

[Ziggo]

So everything is now back to normal and running great. 22psi tune is rock solid, with just a bit of boost oscillation. After getting everything back together I had a boost leak which I traced back to the EGR port plug on the manifold. Got that sealed up using the permatex #2 on the threads. After that I had trouble with blowing the coupler that is on the mini extension between the turbo and the 90* coupler. It was just a 2" dia piece of unbeaded pipe with worm gear clamps so I am not surprised it called it quits. The pipe has been replaced with a beaded version, and 2" tbolt clamps from siliconintakes.com are on the way.

Because of all these issues I never got a clean pass at the drag strip this weekend, and did not make it on the dyno. I did coast to a 14.5 @ 97 after my coupler blew in 4th just after the 1/8th, that has to be worth something....

Now that the 3bar is in, its time to start working on the ramp to 25psi tune and see if the turbo has anything left up top for use on the drag strip. I would not use the 25psi tune for road racing, but should be ok for strip/street use. Once its done I'll hit the dyno to dial in the timing and get some data that should help set VVT.

[skeurton]

Good stuff, @Ziggo. Are you still running/tuning on e85?

EDIT: DOH! Fail. I didn't see the attached log.

[Ziggo]

Originally Posted by skeurton Good stuff, @Ziggo. Are you still running/tuning on e85? EDIT: DOH! Fail. I didn't see the attached log.

Its a 5/7 mix that I am using. We will see how it works, I may drop down to 3/9 if I continue to not see any knock. It appears that some of the knock I was seeing up top might have been due to the seals even though there was no evidence of leaking. I have not seen a return of the small counts of knock I used to get above 5500rpm

[skeurton]

Originally Posted by Ziggo Its a 5/7 mix that I am using. We will see how it works, I may drop down to 3/9 if I continue to not see any knock. It appears that some of the knock I was seeing up top might have been due to the seals even though there was no evidence of leaking. I have not seen a return of the small counts of knock I used to get above 5500rpm

Interesting. I just replaced my injector seals yesterday and had the same observations. I had previously seen consistent counts of knock above 5500 RPM, as well. I had wondered if the stock seals were leaking because I was hearing a louder ticking noise than usual in the past few weeks. I logged a few pulls today and the most knock I saw above 5500 was 2 rows of 0.47 KR.

Here's what my injectors looked like when I pulled them...

[Mistersix]

Originally Posted by Ziggo Its a 5/7 mix that I am using. We will see how it works, I may drop down to 3/9 if I continue to not see any knock. It appears that some of the knock I was seeing up top might have been due to the seals even though there was no evidence of leaking. I have not seen a return of the small counts of knock I used to get above 5500rpm

So this is 5 gallons E85 and 7 gallons 93 octane? Same with the 3/9 mix?

Any advice for someone who wants to run a modest blend for extra knock protection?

[cld12pk2go]

Originally Posted by Mistersix So this is 5 gallons E85 and 7 gallons 93 octane? Same with the 3/9 mix? Any advice for someone who wants to run a modest blend for extra knock protection?

3 gal per tank should be plenty to get your all the way to MBT (or beyond - so be careful if you are pushing timing) without KR or enough to offer plenty of extra protection against KR with an existing tune.

[Ziggo]

No evidence of leaking there either. You have more buildup on the tips than I did, and the shaft stuff looks a little brown which is odd. I didn't have any buildup on the ends, but had some carbon buildup on the sides of the nozzle that easily wiped clean.

[skeurton]

Originally Posted by Ziggo No evidence of leaking there either. You have more buildup on the tips than I did, and the shaft stuff looks a little brown which is odd. I didn't have any buildup on the ends, but had some carbon buildup on the sides of the nozzle that easily wiped clean.

Yeah, the injectors cleaned up pretty easily with some gasoline and a rag. I'm not really sure what that brown stuff is either. When cleaning out the injector ports in the head, I didn't really see any of that. It was all black carbon.

What kind of spark plugs and gap are you running?

[Ziggo]

Originally Posted by skeurton What kind of spark plugs and gap are you running?

ITV22s @ .028"


Zigatapatalka

[Ziggo]

Here is some strangeness for you. Both are the exact same tune except with different boost targets and WGDC tables. Same MAFCAL, same fueling tables, boost leaks make you run rich, maybe a pre-turbo vacuum leak? But then why would it go up and down. I have two logs that show the exact same behavior.



The turbo seems to tolerate 25psi just fine. BATS did not rise unreasonably and I even overestimated the WGDC needed so it has a small boost oscilliation. Per VD I picked up 25hp as well, which is on the low side for a ~2.5psi increase, but that just means the hotside is probably getting pretty backed up.

[rfinkle2]

Hey guys... wasn't sure where to post this but was really interested in the opinions of Ziggo and cld12pk2go of the option to the right of the gtx3071 on this page.

I didn't know up until today that the 3071 could be had with a 3" inlet and 2" outlet.

I have been reading cld12pk's posts about how he is glad he went 3071 and I've already contacted JP and agreed that paying a restocking fee for the 2867 and think it is worth the long run headroom I'll get with the 3071.

Garrett GTX3071R Dual Ball Bearing Turbo : atpturbo.com

[cld12pk2go]

Originally Posted by rfinkle2 Hey guys... wasn't sure where to post this but was really interested in the opinions of Ziggo and cld12pk2go of the option to the right of the gtx3071 on this page. I didn't know up until today that the 3071 could be had with a 3" inlet and 2" outlet. I have been reading cld12pk's posts about how he is glad he went 3071 and I've already contacted JP and agreed that paying a restocking fee for the 2867 and think it is worth the long run headroom I'll get with the 3071. Garrett GTX3071R Dual Ball Bearing Turbo : atpturbo.com

Either turbo will be sweet. The 2867 will likely spool several 100 RPM earlier, but since the GTX3071 spools PDQ, this isn't a big deal IMHO.

I do not have any data on what the efficiency or flow hit might be on the GTX3071 with the smaller compressor housing; however, if you are going for the bigger turbo you might as well not limit the compressor with a smaller than ideal housing...

[Ziggo]

Originally Posted by rfinkle2 Hey guys... wasn't sure where to post this but was really interested in the opinions of Ziggo and cld12pk2go of the option to the right of the gtx3071 on this page. I didn't know up until today that the 3071 could be had with a 3" inlet and 2" outlet. I have been reading cld12pk's posts about how he is glad he went 3071 and I've already contacted JP and agreed that paying a restocking fee for the 2867 and think it is worth the long run headroom I'll get with the 3071. Garrett GTX3071R Dual Ball Bearing Turbo : atpturbo.com

Don't do it. If you are going to get the 3071 don't hamstring it with the smaller ID inlet. You are going to have to get some couplers to connect to your intercooler piping anyway, so you are really only saving on the big turbo TIP. And FYI, I am going to a larger diameter TIP/SRI/MAF as soon as JBR releases it. That and the 5th port setup are the last surrounding pieces I am putting into place. I'll live with that for awhile and see if I really want/need more.

So with @Lex 's help I resolved the lean spot issue. Apparently the injector scaling only works as long as you are not pushing it too hard. Had to rescale the MAF (by 22.5%!)



Log for the run (need to downscale the MAF/load values by 22.5% for them to make sense)
http://www.mazdaspeedforum.org/forum/foru..._4th_60112.csv

[Lex]

Glad it worked out for you too with the MAF scaling. That kind of strangeness makes me a little scared of what's going on behind the scenes with those scalars.

[cld12pk2go]

I have been running a 1.12 scaler for a long time and have never seen any oddities like that...

[Ziggo]

Originally Posted by cld12pk2go I have been running a 1.12 scaler for a long time and have never seen any oddities like that...

I am also running ~twice the ethanol content (E40ish) and probably pushing the stock injectors harder since I am not spraying any fuel in the intake (yet...)

[cld12pk2go]

Originally Posted by Ziggo I am also running ~twice the ethanol content (E40ish) and probably pushing the stock injectors harder since I am not spraying any fuel in the intake (yet...)

Good point, you are pushing the IDC higher.

With the 0.87 latency, I am typically in the upper 70's on IDC.

[Ziggo]

Originally Posted by cld12pk2go Good point, you are pushing the IDC higher. With the 0.87 latency, I am typically in the upper 70's on IDC.

Yeah, I am using .87 latency as well and my IDCs are ~95% I can only get away with it because of boost targeting, load tuning would have my WGDC locked.

[Ziggo]

Since I continue to get questions regarding the coolant drain line I went a took another picture.

1) Its important to slightly angle the banjo bolt towards the compressor housing so that it does not interfere with the manifold flange/gasket. I mocked things up prior to installing them to ensure it all fits together right.

2) Using a plain rubber hose in this location is very risky because of the exposure to the very hot turbine housing. The coolant will keep the hose from getting too extremely hot, but the radiative heat coming off the manifold/turbine housing will eventually make the rubber brittle and prone to cracking. Thus the replacement of this hose with a high temp rated, with a SS braided shield, not only to protect from abrasion, but also to shield the hose from the heat off the manifold/turbine housing.

[dereeek]

Great info. going to start studying this for saturday, when i install mine.

[breakfstincluded]

thanks ziggo that helps a lot (:

[himurax13]

Originally Posted by breakfstincluded thanks @Ziggo that helps a lot (:

I am glad that I put a 6AN line in there. There is a lot of heat in that area. 11.5" is just about perfect.