BNR S3 Swap How To

[Boosted Beluga]

where are you going to mount the ecu?

[Ziggo]

Originally Posted by Boosten Ya(josh) where are you going to mount the ecu?

I am mostly OK with where it is now. Only thing I might change is to add some kind of a shim to stand it off the fuse box better to get better airflow over the heatsink on the bottom.

[bmylez]

That's a funny looking ECU mounting. You would be able to free up the harness enough that the ECU isn't all cock-eyed. What would be sweet is if a company made an ECU harness extender so we could put that bitch wherever we wanted. It would be $$$$ though.

[Lex]

Have you had a chance to quantify how much the larger intake has helped k n terms of airflow and power?

[bmylez]

If I had to guess...over 9000.

[Ziggo]

Originally Posted by Lex Have you had a chance to quantify how much the larger intake has helped k n terms of airflow and power?

Not yet, had to turn a couple MAFCAL revisions first, then have to evaluate the effects on WGDC. I dropped it by 10 across the board to start with, but need to make sure I am spike free. Butt Dyno says the turbo spools even earlier now, which at this point is just stupid. I'll have some information up in the next couple days. Unfortunately the HD on my tuning laptop died, so the only comparisons I will be able to make are to stuff that was uploaded here.

[Ziggo]

@Lex @jbarone

So I the fueling isn't nearly as stable as it was on the CAI, but I have not gone in depth on the MAFCAL either, this is just 2 global multiplier revisions so I may be able to dial it in with a Cell by Cell MAFCAL. Could also be an indicator of needing an airflow straightener in front of the MAF, but its too early to say for sure.

Airflow is pretty much identical to my last posted log with the CAI, but the ambient temperature was 20* lower on the CAI log so I can say with certainty that this will increase airflow significantly if compared at an equal ambient temperature. Note* to obtain actual absolute massflow you need to multiply the number in the Logs by .775 to correct for scaling for my e85 mixture. Both logs are using the same e85 mix, and thus the same correction factor applies to both.

JBR WP Log: http://www.mazdaspeedforum.org/forum/foru...1&d=1341687489

Last CAI Log: http://www.mazdaspeedforum.org/forum/foru..._4th_60112.csv

Virtual dyno results are not really comparable since they were taken on different
stretches of road, but attached it for reference anyway. Red is JBR WP, blue MSCAI

[dan7225]

Virtual dyno results are not really comparable since they were taken on different stretches of road, but attached it for reference anyway. Red is JBR WP, blue MSCAI

so you have less hp/trq with JBR intake?

[Ziggo]

Originally Posted by dan7225 so you have less hp/trq with JBR intake?

Doubtful, back to back logs of the intakes on the same stretch of road would be the only way o directly compare power.

[Dano]

Originally Posted by Ziggo Changed the intake situation around a little bit. JBR WP intake installed. Should prevent those pesky water on the MAF issues I had, and give me some headroom on the MAF sensor , I was exceeding 4.9V before. This should drop it considerably. Rescaled, 4.92v is now 662g/s, before it was 379g/s so I think I have sufficient headroom.

I think its time for a slimmer bat and HTP tray

put ECU back where is was and still have room. IIRC a different group battery will fit in their tray without going to a "slim" bat and you gain 2" of space....

ziggo do you think that would be enough space?

I want a 3 or 3.25 intake and am making my plans. I like the JBR 1 piece idea but think some straighteners would be a +

looking forward to your results and to see if you stabilize your AF curve.

[Ziggo]

Originally Posted by Dano I think its time for a slimmer bat and HTP tray put ECU back where is was and still have room. IIRC a different group battery will fit in their tray without going to a "slim" bat and you gain 2" of space.... ziggo do you think that would be enough space?

I would put the battery in the trunk first. Not that the HTP isn't a decent piece, just that if I am going to make space, I REALLY want to make space, and shifting a few pounds to the rear wouldn't hurt either.

[Dano]

yeah well I haul stuff in my car all the time w seats down, so bat in hatch is not an option for me at this point.


I don't see needing any more than 2 extra inches....lol.... that's what she said anyway

[Lex]

@Dano now I see why you're eager to see my 3" results. I will be doing some back to back testing this coming week.

@Ziggo thanks for the info. The earlier spool alone must be very nice.

[Dano]

Yes. Get off ur ass man!!


Tappin

[Caligula]

Subd

[atvfreek]

Originally Posted by Lex @Dano now I see why you're eager to see my 3" results. I will be doing some back to back testing this coming week. @Ziggo thanks for the info. The earlier spool alone must be very nice.

Lex, did you end up getting back to back test results on intakes? I know I will need an upgrade soon. Even with the CS intake, I have 20+psi on the bnr at 3200rpms. But I'm looking more for top end gains.

Freekn tappin

[Lex]

Originally Posted by atvfreek Lex, did you end up getting back to back test results on intakes? I know I will need an upgrade soon. Even with the CS intake, I have 20+psi on the bnr at 3200rpms. But I'm looking more for top end gains. Freekn tappin

Here is my summary of findings:

1. Go with a 3" or larger but go all the way to the turbo.
2. Use an AEM dryflow filter. It outflows the cotton gauze filters.

Over the SRI alone that should give you 10-20 g/s better airflow up top - it lowers the pressure ratio on the turbo.

[Boosted Beluga]

I found that using the the specture filter gained me around 5g/s over the aem. I'm running a cai and am on stock turbo

[Dano]

could that 5gs be attributed to a brand new clean specture vs a dirty AEM

[Boosted Beluga]

You would think but both of them were brand new.

[Lex]

Originally Posted by Boosten Ya(josh) You would think but both of them were brand new.

I will be trying something that "should" be better than AEM as well - we will see. With the OEM turbo its easy to see the difference since the WG is pegged but with a BNR you are not as boost limited unless you're running it up against its limits as well.

In any case you will at least see a reduction in WGDC if you're not pegging it already in which case you will see an increase in boost, airflow, and spool.

[Boosted Beluga]

Everything was the same except airflow. But its so small of a difference I doubt one will prefer one over the other.

[Dano]

Originally Posted by Lex I will be trying something that "should" be better than AEM as well - we will see. With the OEM turbo its easy to see the difference since the WG is pegged but with a BNR you are not as boost limited unless you're running it up against its limits as well. In any case you will at least see a reduction in WGDC if you're not pegging it already in which case you will see an increase in boost, airflow, and spool.

yeah! lex is official!

hey BTW what is your take on the Amsoil filters? are they cotton weave? Their surface area appears to trump all others but I don't know if they flow more for sure.

[Ziggo]

Trouble is brewing...

[Dano]

yesssssss, it tis....

[Ziggo]

@djuosnteisn LOGS!,

We had a freak cold snap, and it was only 78* at 7am this morning. Note my MAF is scaled 22.5% for my E85 mixture so while I peak a 470g/s in the logs, its actually only 369g/s (49lb/min).. which should be plenty for 400whp.. go go beaner turbo.

Seems to be working great. First log is just letting it pop on and drag me rich to verify its functional.

Second and Third logs are with closed loop enabled, but no MAF adjustments. I am going to need to soften the turn-on somehow, though in 2 stroke with a minimum pulsewidth of 1ms it has some surge. Calculations got me close to my desired maximum DI IDC of 80%, but there is a bit of lag in the system so I need to turn it on a bit earlier, so an earlier softer turn on seems like a good idea. Then its time to adjust the MAF curve as needed.

[Tomas]

Are your cruising BATs always about 30 degress above IAT?
Kinda high no?

[Ziggo]

If you are referring to log 2 it was a very short roll in from siting for 20 minutes. I had a failed flash and had to recover and was inspecting all the lines.


Zigatapatalka

[Caligula]

This makes me want an S3 so bad... sigh but I need new tires soon

[802MS3]

how are you liking the swaintech coating on the turbine housing/mani?

[Ziggo]

Originally Posted by 802MS3 how are you liking the swaintech coating on the turbine housing/mani?

It has discolored from it's pearly white state, but no cracks or flaking so I am pretty happy.

I don't think there is a measurable benefit in performance spool wise, I was after the the thermal insulative properties to protect other things in the engine bay since all the heat shields are gone. Since it has always been on there I couldn't take before and after measurements, but nothing has in the area has melted and plastics appear to be holding up well, not showing any signs of embrittlement.




Zigatapatalka

[Ziggo]

My maf curve is so retarded. Scale up 67% for JBR intake, then another 22.5% for 5/7 mix E85, then subtract 115 from 4.1V and up for AIC1, curve reduction between 3.6 and 3.8 for start of 5th port and flatline between 3.8 and 4.1 as the 5th port becomes fully operational

[Silverspec06]

Here is the easy way to get the EM bolt off under neath it what i did was put a ratcheting with the box end on the nut open away then I slung a 17 mm box end over the open end of the 14 mm put it up between the manifold between the 2 pipes on the passenger side. pull up on it broke loose with no pb blaster and minimal effort.

[Caligula]

Originally Posted by Ziggo It has discolored from it's pearly white state, but no cracks or flaking so I am pretty happy. I don't think there is a measurable benefit in performance spool wise, I was after the the thermal insulative properties to protect other things in the engine bay since all the heat shields are gone. Since it has always been on there I couldn't take before and after measurements, but nothing has in the area has melted and plastics appear to be holding up well, not showing any signs of embrittlement. Zigatapatalka

Is that the plasma sprayed ceramic stuff?

[Domino81]

lawlz at freak cold snap being 78 degrees. I won't see 78 until May, April if I'm lucky.

[vrspeed10]

plenty of great info in this thread. thanks for write up @ziggo

[kritz]

Reused coolant line, we didn't have the new fitting. Necessity is a mother.

Sent from my frontal cortex.

[Ziggo]

Originally Posted by kritz Reused coolant line, we didn't have the new fitting. Necessity is a mother. Sent from my frontal cortex.

That's the coolant feed line, you have to bend it a bit and reuse. The coolant drain is the one I fabbed up a new line for.

[kritz]

Reused both as is,

[1sicms3]

thank you for this thread, im goin to be installing a bnr next week