BNR S3 Swap How To

[1sicms3]

Originally Posted by Ziggo First post updated with link to tuning thread. As for my first impressions, this swap seems to have resulted in similar spool to stock, I cant really tell the difference except by examining logs and even then I am not sure they are comparable since my last log with the K04 took ~500R rpm from 3000 to spool to 20psi @ 70deg and the BNR took about the same to spool to 18.5psi @ 105deg So as a whole spool is similar, but the top end is where the difference is. The BNR is holding 18.5psi to redline without breaking a sweat in 105deg ambients, where the K04 was falling off to 16.5psi @ 70deg.

[1sicms3]

im going with bnr stage 1, would i have to do a retune?

[himurax13]

Originally Posted by 1sicms3 im going with bnr stage 1, would i have to do a retune?

Why?

No.

Sent via blown passenger side speakers.

[He Hate Me]

Just incase anyone needed some new nuts for the Turbo to Mani or Turbo to Downpipe, here is the part #: JE1040355, $6.12 EACH at my dealer!

Some spaces are definitely a PITA with the stock downpipe, but doable. Wasn't able to get my turbo bracket off from the 2 bolts on the block, those suckers were on their GOOD! Even heated, PB'd, LW, them and nothing.

Thank you for this write up as well Ziggo, helped a lot.

Might possible add a 22mm (7/8) Oxygen Sensor Socket to required tools to remove the top o2 sensor on the downpipe to get the stock heatshield off to reach the downpipe nuts.

All nuts for the mani, and downpipe are definitely all reachable from the top, if anyone is wandering.

1/2" breaker bar made life easy for all the nuts.

[himurax13]

Originally Posted by He Hate Me Just incase anyone needed some new nuts for the Turbo to Mani or Turbo to Downpipe, here is the part #: JE1040355, $6.12 EACH at my dealer! Some spaces are definitely a PITA with the stock downpipe, but doable. Wasn't able to get my turbo bracket off from the 2 bolts on the block, those suckers were on their GOOD! Even heated, PB'd, LW, them and nothing. Thank you for this write up as well Ziggo, helped a lot. Might possible add a 22mm (7/8) Oxygen Sensor Socket to required tools to remove the top o2 sensor on the downpipe to get the stock heatshield off to reach the downpipe nuts. All nuts for the mani, and downpipe are definitely all reachable from the top, if anyone is wandering. 1/2" breaker bar made life easy for all the nuts.

The 15mm copper colored exhaust nuts from edgeauto are like a dollar each and are much beefier ...

[silvapain]

Originally Posted by himurax13 The 15mm copper colored exhaust nuts from edgeauto are like a dollar each and are much beefier ...

And because they're copper they don't seize up like the OE ones do.

[himurax13]

Originally Posted by silvapain And because they're copper they don't seize up like the OE ones do.

True but they require a bit more effort to install due to the beefier oval design.

On certain downpipes, only the OEM nuts will work where the downpipe is really close to the stud.

[He Hate Me]

[Lex]

How many of you have installed the latest BNR with the 2 port WG actuator? Have you had issues increasing boost and when you do, it spikes in the upper RPMs?

[beachshoer]

Originally Posted by Lex How many of you have installed the latest BNR with the 2 port WG actuator? Have you had issues increasing boost and when you do, it spikes in the upper RPMs?

THAT doesn't sound good.....

[Lex]

Originally Posted by beachshoer THAT doesn't sound good.....

I've tuned a few of the new ones now and I am seeing a trend in how boost control works. Just want to get more data.

[tokoam]

Originally Posted by Lex How many of you have installed the latest BNR with the 2 port WG actuator? Have you had issues increasing boost and when you do, it spikes in the upper RPMs?

I think you and I were having this issue at the beginning it has since gotten better.. but it still happens with upper gears like 5th or 6th gear it spike's.Boost guage showing 23-24 psi ap showing 22.7 but its only for a split sec and then drops back to 18-19.

[atvfreek]

Originally Posted by tokoam I think you and I were having this issue at the beginning it has since gotten better.. but it still happens with upper gears like 5th or 6th gear it spike's.Boost guage showing 23-24 psi ap showing 22.7 but its only for a split sec and then drops back to 18-19.

Do you have a 3 bar map sensor? Of not then that is the stock map sensor being maxed out at 22.7psi.

[aviator79]

Im confused. So it used to only have one port? Mine has 2, so for now hooked it up like stock as using stock EBCS. When I install my 3 port I was going to use the bottom for the EBCS and the top for my boost only line to Synapse rather than Ting into EBCS line as it is now. Will that work?

[himurax13]

Originally Posted by aviator79 Im confused. So it used to only have one port? Mine has 2, so for now hooked it up like stock as using stock EBCS. When I install my 3 port I was going to use the bottom for the EBCS and the top for my boost only line to Synapse rather than Ting into EBCS line as it is now. Will that work?

Are you talking about the Wastegate solenoid? The recent versions of the BNR Stage 3 come with 2 ports now. I forgot how @Lex; said to route the vacuum lines for it.

[aviator79]

Originally Posted by himurax13 Are you talking about the Wastegate solenoid? The recent versions of the BNR Stage 3 come with 2 ports now. I forgot how @Lex; said to route the vacuum lines for it.

No the wastegate actuator. Mine has the two port just like stock turbo. Dont have time to install my 3 port yet so ran comp port to WG port like OEM and will run top port to stock solenoid like OEM. So did you have to T off between comp port and WG port before if not using a 3 port? IDK, im just curious.

[Lex]

You can run it exactly like OEM but the restriction in the top port is not big enough to give you enough boost from what I've seen.

IMO the new WG actuator is a big step backwards for these turbos. All the new ones have been a much bigger pain to the tune than the old single port WG actuators.

[aviator79]

Not doubting you, but doesnt really make sense if the smaller port is plugged...I just want to be able to drive my car to work in the morning...slowly.

[tokoam]

Originally Posted by atvfreek Do you have a 3 bar map sensor? Of not then that is the stock map sensor being maxed out at 22.7psi.

Nope still on stock map sensor I will eventually upgrade to full 3 but for the time being it is what it is.

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[RogerH]

I just got one of the bnr turbos with the dual port wastegate. is there anything I can do before I install it to make it easier to tune? I have a cobb ebcs I was going to install with it.

[redboat]

Originally Posted by Lex You can run it exactly like OEM but the restriction in the top port is not big enough to give you enough boost from what I've seen. IMO the new WG actuator is a big step backwards for these turbos. All the new ones have been a much bigger pain to the tune than the old single port WG actuators.

would an OEM K04 Wastegate be a better canidate then the new ones on the BNR's?

[manselainen]

I installed a 1 mm welding tip as restrictor in pressure line to WG as there does not seem to be a restrictor there unlike in K04 (I'm reusing stock EBCS). One thing to check: in my kit the copper crush washers for oil feed banjo bolt were too small.

[LatinKraze]

With my install the banjo supplied for the coolant line was damaged. Caused a leak whenever I fed coolant through the system. Don't know if I damaged it or it was damaged but check both faces of the banjo for imperfections. I reused the coolant hard line, custom bent lol, until I found a replacement banjo.

[manselainen]

The banjo outlet supplied with the kit was of smaller diameter than EGR inlet where this coolant return goes. So my 6AN line was loose on banjo, causing a coolant leak. Double hose clamp hopefully did the trick in my case. It seems surprisingly difficult to get these small part kits right

[LatinKraze]

Originally Posted by manselainen It seems surprisingly difficult to get these small part kits right

Only when quality control starts taking a back seat

[manselainen]

This Ziggo's how-to helped me a lot!

I wish I can put here some my experiences without having to write my own. As I continued to run stock parts (downpipe, exhaust manifold, EBCS, TIP) my case was somewhat different. Hope this info may be of some use to others.

- I removed wipers and cowl to get some more room
- I did not remove oxygen sensor but cut the DP heat shield off -> major PITA, I don't recommend it
- exhaust manifold was not removed
- all EM to turbo nuts and studs can be removed from top, same applies for all turbo to DP nuts, studs can be removed later when turbo is on the work bench
- I did not remove turbo brace, just took one bolt off to free turbo
- I removed EGR, one EM manifold stud closest to EGR and heat shield of brake fluid -> turbo was removed from side
- I reused oil feed banjo bolt crush washers as new did not fit
- I reused both oil return gaskets (BNR kit had gasket for oil line to block)
- some glue to hold bolts is your friend when installing oil return to turbo
- I reused all studs and bolts
- stock TIP was not possible to get back on without cutting rubber gasket a bit

[BoostedRide]

Does anyone have the Mazda part#s for the EM to turbo & turbo to DP gaskets?

Originally Posted by He Hate Me Just incase anyone needed some new nuts for the Turbo to Mani or Turbo to Downpipe, here is the part #: JE1040355, $6.12 EACH at my dealer!

How many of these nuts should I order?

[Lex2007]

Originally Posted by BoostedRide Does anyone have the Mazda part#s for the EM to turbo & turbo to DP gaskets?

This stuff works great.

Amazon.com: Permatex 81878 Ultra Copper Maximum Temperature RTV Silicone Gasket Maker, 3 oz. Tube: Automotive

Amazon.com: Permatex 81878 Ultra Copper Maximum Temperature RTV Silicone Gasket Maker, 3 oz. Tube: Automotive
Amazon.com: Permatex 81878 Ultra Copper Maximum Temperature RTV Silicone Gasket Maker, 3 oz. Tube: Automotive

[BoostedRide]

Originally Posted by Lex2007 This stuff works great. Amazon.com: Permatex 81878 Ultra Copper Maximum Temperature RTV Silicone Gasket Maker, 3 oz. Tube: Automotive

I want to do it right as I am not doing the labor myself.

[Lex2007]

Originally Posted by BoostedRide I want to do it right as I am not doing the labor myself.

Hey I've used that stuff when hard gaskets weren't readily available and it worked just as good. But I see your point.

[some call me...Tim]

Originally Posted by BoostedRide Does anyone have the Mazda part#s for the EM to turbo & turbo to DP gaskets?

From what I've seen, there seems to be a little confusion so someone correct me if I'm wrong but I believe you want L3K9-13-710 and L3F2-13-490. Onlinemazdaparts has good (relatively) prices.

[neganox]

DP gasket - Mazda OEM Downpipe Gasket (Upper) MS3 MS6

Turbo to EM gasket - Mazda OEM Manifold Turbo Gasket MS3 MS6

Studs incase some snap - 10mm (1.5 pitch) Stud

Locking nuts - 10mm (1.5 pitch) Nut Locking Head

[Darthspeed3]

Great write-up to the op!! I'll definitely use it this spring

[Project_dog]

Do you need to run a oil restriction bolt on a bnr s3 ?

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[taf0422]

Originally Posted by Project_dog Do you need to run a oil restriction bolt on a bnr s3 ? Sent from my SAMSUNG-SGH-I337 using Tapatalk

No.

[neganox]

Oil restriction bolts are a band-aid for a smokey turbo. No.

[Project_dog]

Okay. Thank you. Just got one for my cx 7. Can't wait to get it

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[Lex2007]

Ziggo, so its been a few years since you installed the BNR S3.

How has it treated you?

[Ziggo]

Still running strong. I had the issue with the housing bolts backing out that the early units did, but other than that I have had no issues. Drive it every day almost on my 5/7 E85 mix map.

[Lex2007]

Awesome! How many miles if you don't mind me asking?

Few more questions:

-Not sure if you have emissions testing in Tx, but we do here in Maryland and my concern is whether I would pass emissions. There is no visual, they just plug into OBDII port.

-Did the OEM clutch withstand the added torque?

-Whats your MPG, out of curiosity? (I have a long commute.)

- Any PCV issues with the additional boost?

Thanks for your post and for sharing your experience with us.