MS6 BNRS3 install

[Stew]

Turbo started smoking recently and I decided it was time to take the leap and get a bigger turbo. I decided on a BNR because it seems to be one of the easier installs and I am not ready to go really big turbo. I will be installing it next week and then getting a tune from @Lex;
I just installed my DO Meth kit and while installing the boost actuated controller, I realized that I will be needing at least 3 boost sources for my install as I also ordered a Gaurdian Angel. Where do all of you tap into boost? I am assuming you don't just add 3 "T's" to the boost line into the BPV. I currently need boost sources for my Boost gauge, WMI controller, and GA. I don't know if I will need one for the boost dial as well or not.

[Status Update]

Subbed for results! looking forward to seeing what numbers you put down

[Stew]

Lex said to go straight to a D010 nozzle for the meth. I would like to get close to 330 hp and 350 tq. I think those are reasonable numbers. 350 hp would be my ideal goal.
Stewart

[Status Update]

I might copy your build later on as those are roughly the same numbers im looking hit.

[Lex]

For the boost sources here's what I use:

1. The GA will simply interrupt the line to your BPV
2. Connect the WMI controller and boost gauge to the line going to the BPV
3. The boost source for boost control will come off the BNR S3 compressor housing.

[breakfstincluded]

Wish my hks worked with GA

[Swinger13]

Originally Posted by Stew Lex said to go straight to a D010 nozzle for the meth. I would like to get close to 330 hp and 350 tq. I think those are reasonable numbers. 350 hp would be my ideal goal. Stewart

Same wheel (gt28) and a lot of your mods mirror my mods too. The only major difference it looks like is I don't have meth.......(yet )

Interested to see what happens. GL with this set up

[Stew]

Yes. I have been following your build. I was hoping since you got those number without that I could get 350 with. We'll see.

[Swinger13]

Originally Posted by Stew Yes. I have been following your build. I was hoping since you got those number without that I could get 350 with. We'll see.

My latest numbers uncorrected 350whp and 370 wtq was in 10~ degree celcius so like 46 ish fahrenheit? your power goals seem within reach. I'm also at 2200 ft so a marginal loss there.

[Stew]

Turbo is now in after a fairly painful install. Probly just because I am a rather inexprienced mechanic. And that oil return line is the biggest pain to get out and even more to get back in on the MS6. Started the car with an appropriate base map, and AFRs started going lean after a few minutes of idling. Did a boost test tonight and @Lex; told me I had the boost dial hooked up wrong. Fixed that and a T-bolt clamp I forgot to clamp down. That fixed AFR's until I drove it. Did a few WOT pulls and an MAF cal log. Realized I had my GA set to activate and too little boost. and something must have come off or loosened because idling AFR's are back to being lean as in AFRs are in the 18 range.

[Swinger13]

Originally Posted by Stew Turbo is now in after a fairly painful install. Probly just because I am a rather inexprienced mechanic. And that oil return line is the biggest pain to get out and even more to get back in on the MS6. Started the car with an appropriate base map, and AFRs started going lean after a few minutes of idling. Did a boost test tonight and @Lex; told me I had the boost dial hooked up wrong. Fixed that and a T-bolt clamp I forgot to clamp down. That fixed AFR's until I drove it. Did a few WOT pulls and an MAF cal log. Realized I had my GA set to activate and too little boost. and something must have come off or loosened because idling AFR's are back to being lean as in AFRs are in the 18 range.

Vacuum leak most likely after the turbo. Boost leak test again!

[Stew]

yep. but no need to this time. Saw it as soon as I opened the hood. The boost tube from the turbo to the intercooler partially came off. I need a smaller tube.

[aviator79]

Installing mine now. Ive got everything undone except oil and coolant. Trying to determine how I get these off. Oil feed is easy but oil drain not sure. Assume coolant feed line is a PITA too with PTO in the way.
Any help?

[Code Monkey]

Originally Posted by aviator79 Installing mine now. Ive got everything undone except oil and coolant. Trying to determine how I get these off. Oil feed is easy but oil drain not sure. Assume coolant feed line is a PITA too with PTO in the way. Any help?

You have a helper?

For the oil drain, small hands and lots of patience.

For the coolant drain, it is easier if you have one person under the car, then from the top you unhook the coolant drain from the T-case while the person underneath puts some rags over so that coolant loss is minimal. With the coolant line freed, you will be able to tilt the turbo and unhook the line from the turbo, then put it back on the T-case and clamp.

I would use new clamps for all the hoses, the clamp on my coolant line was worn out at the T-case and had a subtle coolant leak after the install. Fortunately, the shop was able to sneak a new clamp on the hose without taking anything apart, but imagine if that was the connection at the turbo.

[aviator79]

Working alone. Got bottom oil drain off block. Had to run to sears to get 6pt 8mm and did 2nd bolt from bottom.
Had to turn clamp on diff cooler and got that off. Plugged with a bolt with electrical tape wrapped around it.
Turbo out.

Can BNR be installed before work tomorrow...that is the mystery

What sucks is all I have is Zyrex which is blue and so when I add it to replace the antifreeze I lost my coolant will turn brownish..

[aviator79]

If Im using stock EBCS do I hook comp port to WG like OEM?

[breakfstincluded]

i think theres a diagram on stratified for this, look at their 2 port mode

[Stew]

Yeah, the oil drain is a pain in the butt.
So far everything is going ok for me. Still have not done a base line VD. I think I am driving Lex a little nuts because I am not used to having to consult someone else as far as mechanical fixes to different problems.
Right now I am fighting some sort of throttle body issue. The car throws a P2100 code and will run very rough and the gas peddle will not work. However, usually, I can restart it and it will be fine. But sometimes it takes multiple restarts before it works. It will even happen while driving. I will lose power, the DSC light will come on, and I will have to restart. I think it could be a poor connection at the throttle body so I am trying to dissasemble the connector to tighten the pins. Have to see if that works.
Stewart

[Stew]

Well I haven't really kept this thread updated, so here is where I'm at. Car is running solidly. Fourth iteration of the tune on the car and it pulls pretty hard. 2nd pulls like a mother, 3rd and 4th are a little meh. Averaging out the number on the Vdyno (runs are both ways on the road) I have about 320 horse and 325 torque. Pretty good numbers and well on the way to reaching my goal of ~350 WHP and TQ.
STew

[redboat]

how's the car running now?

[Stew]

Running like a champ. Pulls pretty hard. But had to promise my girlfriend no racing :/ LOL

[kish89]

Originally Posted by Stew Well I haven't really kept this thread updated, so here is where I'm at. Car is running solidly. Fourth iteration of the tune on the car and it pulls pretty hard. 2nd pulls like a mother, 3rd and 4th are a little meh. Averaging out the number on the Vdyno (runs are both ways on the road) I have about 320 horse and 325 torque. Pretty good numbers and well on the way to reaching my goal of ~350 WHP and TQ. STew

Why is there such a big difference in numbers between runs?

[Stew]

Road wasn't completely flat. Doing runs going both ways.
Stew

[Mistersix]

Glad to see it's coming along. You need to find a nice flat spot for those VD runs though.

[Stew]

I got one. My ambient temps are fairly cool right now so power is looking pretty good. Did another vdyno on a flat spot and I'm looking at about 330 hp 335 tq. Will load up another vdyno after I get my next tune from lex.

[Mazdazilla6]

@Stew; How does the 3.5" intake fit with the s3? Did you relocate your battery before you swapped the s3?