Home

Instructions - Flyin` Miata

1. 15 Section 7 Mount Turbocharger Assembly 16 Section 8 Oil LINES ee 21 Section 9 Water Lines ee 22 Section 10 Mount Intercooler 23 Section 11 Re routing coolant 25 Section 12 Install Fuel Injectors FMII and FMIIR only 26 Section 13 Intercooler Tubes 28 Section 14 Compressor Inlet 30 Section 15 Trim Mouth Radiator Inlet Duct 33 Section 16 Trim Splash Pan 35 Section 17 ECU Vacuum Line Connections 39 Section 18 Miscellaneous 41 Section 19 Heat Shield 43 Section 20 Boost Control 44 Section 21 General Rules of Operation 46 Section 23 Maintenance ee 46 Fiyin Miata 3 Rev 6 3 970 464 5600 Tool and Eguipment Reguirements Every project on your Miata presents the opportunity to purchase more tools Below are the tools you will need for the successful installation of this turbo kit metric open box end wrenches metric socket set clean rags assorted slot and Phillips screw drivers metric allen wrenches teflon thread sealant paste NOT tape floor jack jack
2. Flyin Miata FM turbo kit installation instructions 20 1 XX XX Flyin Miata 499 35 Rd Palisade CO 81526 tech line 970 464 5600 www flyinmiata com Introduction Thank you for purchasing the Flyin Miata turbo system We regard the installation as a mutual proj ect and will be pleased to offer help at any time We remain committed to make this a successful and enjoyable experience for all concerned These instructions will offer the installer a guide for the instal lation and operation of the Flyin Miata turbocharger system for the first and second generation 90 05 Mazda Miatas Any instructions that don t apply for all years are clearly marked STOP DO NOT DEVIATE FROM OR SKIP ANYTHING IN THESE INSTRUCTIONS UNLESS YOU TRU LY UNDERSTAND EVERYTHING ABOUT WHAT YOU RE DOING WHEN IN DOUBT CALL US INCORRECT DEVIATION COULD BE A VERY EXPENSIVE MISTAKE Please read through these directions entirely Evaluate your own skills honestly and decide whether this installation is something that you are comfortable doing Realize that you are doubling the horse power of your car and the consequences of improper installation could destroy your engine To install this kit safely you must have a firm grasp of how cars work Proper tool use is critical We are more than willing to help anyone install this kit but you must be honest with yourself with respect to your skill level before you jump into the deep end These directions
3. ably needs to be cleaned Unscrew the top of the valve use a strap wrench if necessary but pay attention there aren t many threads holding it in place and there s spring tension that s going to try to eject the top If you re not careful it is possible for the threads to be damaged on both removal and reassembly Remove the spring and piston then thoroughly clean the piston and its bore Re oil the piston and bore using a light oil something like Tri Flow don t use a thick engine oil and reassem ble Again be sure to get proper thread engagement it s easy to damage the threads if the top push es off Flyin Miata 47 Rev 6 3 970 464 5600
4. bottom of the intercooler Mark and cut po 1 these after the rest of the pan is complete Again these guidelines are just a rough be needed Please look at the pictures to clarify any questions NOTE The forward piece that will be left after trimming willbe difficult to fit between the two segments of the intercooler out hose Since the hose is flexible that portion of the pan can often be finagled into position by bending the hose a little If not there are two options The easiest option is to trim more of the pan off but it s preferable to leave as much of it intact as possible The second option is to remove the intercooler outlet hose from the intercooler install the pan then re install the hose The hose can be difficult tof re attach but it is possible On some cars it s easier P to put the hose clamp on the intercooler get the hose over the lip of the intercooler then slide the hose clamp onto the hose Finally slide the hose the rest of the way onto the in m tercooler and tighten down the hose clamp s Flyin Miata 36 ase 970 464 5600 99 05 Cars Only 1 Unfortunately trimming the splash pan is not quite as straightforward as trimming the mouth How ever there is only a little variation between the two generations the dimensions are basically the only things that have changed As with the first generation more experimentation will be required to get the prop
5. however 2 Keeping the compressed air running tap the threads with z the supplied 3 8 NPT tap Measure the distance from the surface of the drilled hole to the closest edge of the pickup tube then wrap tape around the tap at a distance a 1 4 less than what you measured from the end of the tap This will ensure that the threads are completely cut but the tap is still far enough away from the oil pickup Grease the tap st stab to help collect the shavings Use a socket and extension to s spin bike tap Again make sure that the tap goes in straight Do this by hand spin it in by hand a couple turns back it out one turn and repeat 3 Clean the surfaces as thoroughly as possible using a thinner or something similar Otherwise the adhesive used in the next step won t stick 4 Put JB Weld epoxy or silicone sealant on the threads of the 3 8NPT gt 5 8 hose barb 36 50020 and screw it in tightly Grease the inside of the 5 8 hose 36 40231 and slide it onto the fitting Route the hose upward so that it can be accessed from the engine compartment 5 Remove the oil drain plug and place a clean catch pan under the oil sump Attach a funnel to the top of the hose and pour the mineral spirits down through the hose to clean out shavings 6 Allow the solvent to drain for approximately 15 minutes before replacing the sump plug Remove the hose from the sump and set it aside for later use If the hose is difficult to remove cut it at t
6. inboard closer to the IW engine hose should be 30 long and the outboard closer to the fender hose 36 long We include one 66 length of hose cut it accordingly You ll need to push each hose onto the banjo fitting 02 70520 hose barb then slip them onto the banjo bolt 02 70525 Be sure to place a crush washer 04 38015 on either side of the banjo fitting while installing them onto the turbo Try to orient the hoses so that their natural curve points them towards the front of the engine Slip the heatshield up as far as possible and secure the hose and heatshield with the 3 8 hose clamps 36 70202 The outside banjo fitting should be left loose it will be removed after the next step Flyin Miata 16 Rev 6 3 970 464 5600 5 Standard Turbo GT2560R Only Using the supplied 3 4 loom clamps 36 70500 secure the Water lines to the gold or silver bracket attached to the compressor housing on the turbo Be sure that the loom clamps are oriented so that the bolt is above the water line as in the picture Again the loom clamps need to go around the hose and heat shield Be sure that the lines don t have any kinks in them aren t too tight and aren t too close to the exhaust manifold The inboard line will go to the upper mounting point 2 the outboard line will go to the lower mounting point 3 The picture shows the turbo assembly already mounted on the engine however the bracket for the water lines is easier to ac
7. routed whatever trimming that is nec essary should be obvious On zaj a na E Eez Flyin Miata 38 Rev 6 3 970 464 5600 Section 17 ECU Vacuum Line Connections Bags to use 7A 7B 8A Refer to the appropriate ECU installation manual for instructions on ie the ECU electronic boost control and other related items now THE VOODOO BOX MUST BE TUNED WITH A WIDE BAND IT IS NOT PRE TUNED 1 Insert a check valve 36 90010 in the vacuum line going to the solenoid that feeds the charcoal canister Be sure that you put it in the correct line the one between the manifold and the solenoid not the line between the solenoid and the canis ter and in the correct orientation with the blue side towards the solenoid Refer to the picture for clarification The second check valve if pres ent is used for cruise control refer to the next section 2 Use the vacuum tee 36 50250 provided to source signals for anything that needs to see vacuum or boost This will include the BOV boost gauge cruise control and MAP sensor if so eguipped For the MAP sensor it s very important to get the cleanest signal possible Only sealed items with very little fluctuation e g boost gauge MSD timing box etc should share the line with the MAP sensor Also it is preferable to have it come into the manifold in the middle If this is not possible the front of the manifold is the next best thing 99 05 cars have
8. 27 12467 then tighten the oil line onto the swivel fitting by getting it finger tight then turning it another 1 4 turn The flare can be dam aged dont overtighten it 3 96 05 Cars Only Route the oil supply line 27 32280 across the rear of the engine on the fire wall and around the rear of the turbo Attach it to the swivel fitting 27 12467 on the turbo Put a couple of drops of oil on the flare then tighten the oil line onto the swivel fitting by getting it finger tight then turning it another 1 4 turn The flare can be damaged don t overtighten it Add the 18 piece of rubber hose 36 40220 around the line where it would otherwise contact the brake mas ter cylinder and brake lines You ll need to slit the hose to fit it around the braided line Retain with a single 3 8 hose clamp 36 70202 i TEH a a eee 7 Oi feed line comes up g 7 dJa o to ihe turbo from below a Gil feed line comes down from Insulate ine hose where the fire wall to the iop af the turbo f i i MA a E i 4 i a it would rub on the body nsulate the line where it car F touch any oth ET mona nts 90 95 4 Tie wrap the oil line in a few places to secure it Use additional tie wraps to keep the oil line from contacting the turbine housing and any other damaging heat sources Caution The stainless steel braid will chafe completely through brake lines hoses and body metal Ensure that the line is not allowed to rub on anything th
9. Bring some heat resistant gloves as well as the necessary tools with you on the test drive As you might imagine things can get pretty warm around the turbo Be sure to crack the locknut loose before taking the arm off of the wastegate as the rod will twist otherwise which could tear the diaphragm inside the actuator Also make sure to tighten the locknut every time you adjust the boost Be careful with the C clip they re very easy to lose You should hold a mag net next to the C clip as you re removing it otherwise you re very likely to lose it Keep in mind that this is something of a trial and error procedure Once the boost has been properly set dou ble check the locknut 7 FMIIR only The included external wastegate comes with two 7 5 psi springs Running both will give you roughly 15 psi 1 bar of boost running one will give you 7 5 psi 1 2 bar Tune with one spring then install the second to tune the increased boost Additional information about boost levels Decreasing the backpressure in your exhaust e g 3 exhaust removing the catalytic converter running a short dump pipe etc can increase the boost level If you are running too much boost for your setup e g you re running too lean on a Voodoo setup or you re over 12 psi on an NA or 10 psi on an NB you need to do something to bring the boost back down You can decrease the preload by moving the wastegate actuator towards the turbine that means washers between
10. a nipple in between two of the runners that looks ideal for sourcing a signal however this nipple does not go through to the man ifold Don t use this to source the signal for anything Sourcing a clean signal is not quite as critical with the other items but you should still be sure that the signal will show both vacuum and boost The signal line for the charcoal canister can be good for these items e g BOV Be sure that there is nothing such as a solenoid that could interrupt the vacuum boost between the source signal and the piece using the signal There are examples of connections following but they are just that examples As long as you have an understanding of what s needed you can modify it as needed The arrows are as follows 1 MAP line for the Voodoo box Hydra Link etc boost gauge line MSD timing box line 2 BOV bypass line This line will sometimes need to be tee d into the cruise control line 90 93 Flyin Miata 39 Rev 6 3 970 464 5600 Flyin Miata 40 Rev 6 3 970 464 5600 Section 18 Miscellaneous 1 90 97 FMIl and Eid a upa 1 di iz Ti al Ki J NE 94 97 Voodoo ay e ay TEN j Ga A Cars Only If the dn m Ei pi lt 4 car Is fitted with cruise control the controller has to be remounted in front of the brake master cylinder as shown below Use the bracket 1 02 50090 supplied with the kit Pay at tention to the rout ing of the cable as
11. be removed as well 16 The pictures below show the parts that will need to be removed from the different cars Keep in mind that there may be extra parts in the picture relative to your car and the kit purchased For example not all 90 97 cars will have cruise control to remove the brackets from and Voodoo kits retain the factory injectors If necessary the fuel injectors will be removed according to the ECU instructions Some parts might be slightly different as Mazda changed things throughout the years For example some of the fuel injectors will be a different color For Voodoo kits you ll need to retain the MAF AFM that s shown in these pictures gt Bend water pipe back and Flyin Miata 970 464 5600 Flyin Miata Rev 6 3 970 464 5600 Section 3a Slot frame rail lip Voodoo Voodoo ll FMII except 3071 turbo no electronics kits only The orientation of the compressor on the turbocharger makes it necessary to slot the frame rail lip on the left side of the car While this might sound intimidating it s a simple process Refer to the picture to get an idea of what the slot will look like and to clarify any dimensions specified This method versus one in which all three edges are cut is used to preserve as much frame integrity as possible Once the slot is done finish the raw edges of the slot with some touch up paint If none is available clear nail polish is a good way to protect the bare meta
12. configured refer to step seven in this section Re attach the outboard water line 12 1f the turbo isn t fitting perfectly with the hoses and such you could rotate the compressor hous ing Loosen the six bolts that hold the compressor housing to the center section Gently rotate the housing as needed being sure to keep the housing parallel to the center section It shouldn t need to be rotated much Bear in mind that it s relatively easy to damage the impeller wheel if the hous ing isn t Square and a damaged impeller requires a turbo rebuild Once the compressor housing is properly oriented check the rod that comes out of the wastegate actuator Be sure that the rod won t contact the edges of the piece that it comes out of Pull the rod out by hand to be sure that there s no contact anywhere in its travel If it does make contact re orient the actuator bracket until the it clears Finally tighten the six screws Get the bolts snug but don t go crazy you are tightening into aluminum 13 Secure the exhaust manifold with the factory nuts Start with the center nut and move out to the ends in an alternating sequence 14 94 05 Cars with stock ECUs only Voodoo Voodoo Il and cars using stock ECUs tem porarily for emissions testing Attach the EGR tube wes 97 22 60200 99 00 aloe 01 05 06 96000 to the fitting on the 4 runner on the NET exhaust manifold Unbolt the bracket holding the EGR tube at the rear of the head to allow more mo
13. for both sides intake 04 70000 and ex haust 36 10455 are the default option with no electronics FMII and FMIIR kits An EGR pipe is an upgrade option for those swapping back to a stock ECU for emissions testing This isn t an option for cars permanently running stock ECUs e g Voodoo kits as you ll get a check engine light However Hydra equipped cars don t use the EGR anyway so the plugs can make installa tion easier Bear in mind that if you have to have the emissions tested the EGR will need to be connected at that time to ensure you don t get a check engine light You wll have received one bolt plug and one plate The plug is for the exhaust manifold thread it in using anti seize The plate is to replace the EGR valve The hole on the back of the intake manifold where the EGR pipe originally connected will remain open This is open to a passage which goes to the EGR valve so closing that hole is unnecessary 16 Non FMIIR kits only FMIIR kits should follow the instructions on the next page Connect the downpipe 22 46XXX to the turbine outlet casting and the catalytic converter Be sure to apply high temp anti seize to the studs first There is no gasket used between the cast outlet and the stainless steel downpipe There are slots at the top of the downpipe to allow rotation to help ev erything align properly Use the M8x1 25 lock nuts 36 20120 and lock washers 36 30300 here These nuts can be pretty challenging to acces
14. it can melt if it s too close to sitting on hot exhaust parts 2 90 93 Voodoo cars only Bolt the cruise control relocation bracket onto the actuator then bolt it onto one of the shock mount top hat studs Ex periment different orientations to see what fits best 3 If the car is fitted with cruise control you ll need to use a check valve 2 on the vacuum line the same valve used in step 1 of section 19 Cut the vacuum line running into the actuator in an ap propriate place to locate the check valve Insert the check valve into the vacuum line being sure that the blue side points towards the actuator Be sure to put the check valve immediately in front of the actuator so that it doesn t interfere with anything else that might be teed into that line 4 Remove the spark plugs and set the gap down to 028 If the car still misfires decrease the gap to a minimum of 025 or replace the wires You can try a bigger gap but it s typically more effort than it s worth We ve had the best luck with a combination of Magnecor 8 5mm wires and NGK ZFR6F 11 plugs Other products wires in particular we ve seen have been much more likely to misfire Flashy performance wires are still prone to misfires The Magnecors are the only reliable wires we ve found 5 Reinstall the oil drain plug then fill the engine with oil Reinstall the coolant drain plug and refill with the appropriate coolant mixture DO NOT use more than 50 antif
15. paint pen or marker and trace out where you re going to cut The cutting should start after you re satisfied with the layout Metal shears seem to be the best tool for this job There s a good chance that further trimming will be required after the mouth has been test fit 1 Left Side Find the second rib from the front refer to the picture and begin the trimming there This rib will be followed down the left side and across the middle 2 Right Side Do not follow the second rib all the way up the right side The second rib should be followed up the right side for about 4 starting at the bottom From the stopping point cut to wards the back of the mouth at a 100 angle relative to the previous cut The mouth may require additional trimming but it should be test fit at this point The mouth can be close to the hoses but it shouldn t touch any of them Trim any of the edges that are doing this Flyin Miata 33 Rev 6 3 970 464 5600 2 99 05 Cars Only Before you start cutting its usually a good idea to take a paint pen or marker and trace out where you re going to cut The cutting should start after you re satisfied with the lay out Metal shears seem to be the best tool for this job Starting at the right side of the mouth cut into it at a point on the vertical face that is 3 3 4 down from the rear mounting point Cut straight across until you get to the middle rib then angle down so that your cut finishes right where t
16. points down as it does in both pictures This hose clamp can be tightened now 7 The BOV supplied with the kit can be set up to vent to atmosphere default on FMII FMIIR and no electronics kits or it can be recirculated and vent back into the intake default on Voodoo and Voodoo Il kits If the stock MAF AFM is retained the BOV must be plumbed to recirculate If the car has been converted to a MAP setup e g a standalone ECU such as the Hydra is being used the BOV can be plumbed either way A vent to atmosphere setup will make the sound more noticeable If the BOV is being used in a vent to atmosphere setup you ll need to get a small cone filter and the appropriate fitting part numbers 05 90936 and 05 16041 contact us and attach it to the outlet on the BOV using the hose clamp on the filter You must install the included small cone filter to ensure that no debris enters the BOV If you d like to set up the BOV to recirculate leave the outlet open for the time being the BOV will be plumbed in the next section The Turbosmart BOV is unique in that you can spin the nipple for the vacuum line without loosening anything Do so to aa the best orientation when you a G connect the signal line section 18 of gt Flyin Miata Mm O oa 970 464 5600 99 05 Cars Only Bolt the aluminum air box into place Fit the rubber gasket 36 90050 around the top of the air Section 14 Compressor Inlet Bags t
17. solutely sure that this hose can t be damaged e g cut by chafing or melted by falling onto the exhaust manifold If you re planning to run mechanical manual boost control not electronic then you won t need the boost control solenoid referenced in the ECU manual Be sure to leave enough hose to allow for the proper location of your boost controller electronic or manual and zip tie the hose onto the hose barbs to ensure that it doesn t blow off 2 If you opted for the manual boost controller not a good idea for Voodoo kits you ll need to install it Bolt it to the smaller of the two bolt patterns on the air box Then connect a vacuum line to the wastegate actuator and connect the other end to the wastegate nipple on the boost controller Next connect the other nipple on the boost controller to the brass fitting on the compressor hous ing Adjusting the boost is simple just turn the Knob towards the to increase it and towards the to decrease it Be conservative and start low This boost controller is relatively sensitive so only change it a few clicks at a time until you ve gotten a feel for how the clicks correspond to boost Be sure to keep an eye on your boost after you changed the controller you don t want to run too much If you have a boost spike on tip in when the boost first starts to build remove the nipple opposite the wastegate arrow remove the ball and spring and reinstall the nipple The instruc tions fo
18. the bracket and the compressor housing on the 2560 be sure you have proper thread engagement or loosening the rod on a 3071 Dont loosen it too much as that will result in slow spool more lag If you believe the problem is due to too little backpressure Such as from the possible causes listed above we do have restrictors for both 2 5 and our 3 exhausts Flyin Miata 45 Rev 6 3 970 464 5600 Section 21 General Rules of Operation e Once you re ready have a helper start the car while you watch for coolant oil or fuel leaks As the car warms up you will likely have a fair amount of smoke as greasy fingerprints burn off and paint cures e Use the best premium fuel at all times This means 91 93 octane R M 2 method which is what s used in the US e Do not use maximum boost for more than 30 second durations e f any sounds of rough combustion occur don t use boost until the cause is identified and correct ed e f you hear knock from the motor take your foot off the throttle immediately These forces are the most damaging Knock sounds like marbles in your engine e Keep an eye on the boost gauge If you see the boost pressure exceeding your target boost level lift off the accelerator pedal We recommend no more than 12 psi on stock 94 97 engines 10 psi on 99 05 engines Poor tuning can also cause serious engine damage so please be sure to properly tune your car Seek professional help if need be If its one of our engine man
19. the filter side discarded The wires will be routed in a later step 94 97 MAFs sit mostly i inside the airbox upper picture 99 05 MAFs sit mostly outside lower picture 970 464 5600 11 90 93 Voodoo kits only Connect the factory airflow meter to the compressor inlet 22 504XX The meter will need to be upside down Attach the included adapter 05 90000 to the opposite side of the meter Be sure to put the diagnosis box adapter 22 31050 between the meter adapter and the nut on the front lower stud Remove the diagnosis box from its mount then remove the mount You may want to hold onto this piece it will be used if you upgrade to the FMII later Attach the hose with a sharp bend 22 50500 to the adapter the end with the sharp bend will connect to the adapter Next connect the support 22 40215 to the hose then attach it to the chassis where the diagnosis box was previously attached 8 Finally route the wires for the diagnosis box and the diagnosis box itself over to the previously installed adapter and secure it 9 12 Secure the air filter to the air filter mounting pipe or MAF Adjust the connections at the compres sor and air filter to best locate the air filter in the air box Be sure that the air filter does not contact anything other than the mounting pipe Once everything is aligned tighten both clamps On 94 97 cars be sure that the filter is all the way on the MAF as it will most lik
20. you just made 1 and 4 from the vertical face to the original marks 3 8 and 4 5 8 from the vertical face That s the template for the top cut Now run 1 down vertically the vertical face on the frame rail which runs fore and aft and make marks that line up with the 1 and 4 marks made in the second step Connect those two marks then trace a line diagonally up to the 3 8 and 4 5 8 marks 2 Cut along the lines you just scribed a cut off wheel should work well Try to make all of the cuts as straight as possible as you ll be welding our plate where you made the cuts Look at the shape of the plate and make sure that the hole you ve cut matches it 3 Weld the plate in your battery is disconnected right then paint it to protect it from rust both the plate and the exposed edges in the car will rust otherwise You can try to get it close with off the shelf paint or some automotive shops such as NAPA will mix a spray can of paint to your specif ic color Flyin Miata 11 Rev 6 3 970 464 5600 Section 4 Oil Return Line Bags to use 2A 5A Drilling and threading a hole in the oil sump is a perfectly safe process Should any shavings slip through they will find it very difficult to get off the bottom of the sump and into the oil pickup For rub ber drain lines the drain hole location is 2 below the upper lip no lower and as far forward on the left side of the sump as possible directly under the A C compresso
21. 0303 238 and 2 75 36 70308 288 at the intercooler to attach the hose Don t 4 tighten the clamps until both ends are properly located It s typically a good idea to get the compressor side all the way on first as its more difficult than the intercooler side to fit If its difficult to get the hose onto the compressor try spraying some alcohol based hairspray on the inside of the hose or the outside of the compressor outlet This will provide lubri cation to get the hose on but will dry sticky to help the hose stay on If you don t have hairspray rubbing alcohol should work well The main goal is to get something that will dry completely soapy water will stay wet This can be espe cially helpful with the small turbo 2554 as the adapter makes it more awkward to get the hose on Be certain that the hose clamp is completely on the compressor outlet If it s not it ml par the hose off of the turbo i F ER me Weave the intercooler outlet hose 22 50200 up so that it sits just below the a DS throttle body The end of the hose with the F 4 Fag bik new Ti oo 1 sharper bend will connect to the intercool Ka a nam 4 er Attach the intercooler end of this hose tolg the intercooler using one of the 2 75 T bolt clamps 288 but leave it loose for now This will allow the hose to be rotated to better line everything up Let the other end hang loose for now yin Miata 28 Rev 6 3 970 464 5600 4 Th
22. 05 Cars Only If so equipped the power steering cooler the metal line attached to the front bumper support might need to be relocated slightly It s a good idea to test fit the intercooler first At the right most end of the cooler near the 180 bend remove the mounting bracket The factory bracket can be used but it should be re oriented so that it points up instead of down If it s difficult to get apart try wedging it apart by twisting a flat head screwdriver between the two tabs The wider the blade the better Be careful to not stab the cooler and be sure that the cooler does not get kinked 5 Check the location of your horn If it will interfere with the intercooler either bend the bracket and or relocate it there should be a location nearby 6 Remove the two bolts that hold the hood latch Check the bolts including the back side for rust as they can look fine from the front but be rusted in the back resulting in broken bolts If you find rust spray a penetrant onto the rust and let it sit The intercooler mounting brackets will slide between the hood latch and core support The AC lines at the bottom of the condenser may need to be bent out of the way If these do need to be bent do so carefully Reuse the hood latch bolts and bolt the assembly back onto the core support The bottom of the intercooler will be located by the intake hoses 7 Be aware that if you opted for the larger intercooler may need to move power s
23. 10 This one is for 01 05 cars the 99 00 version is very similar the 90 93 version is somewhat similar and the 94 97 version is different 22 Intercooler out hose 22 50200 This goes between the intercooler and the throttle body junction pipe 23 Oil drain hose also now black Bag 5X 22 8003X 24 Weather stripping for the air box 36 90050 25 Outlet this one s now black too 22 20100 26 Compressor outlet hose 22 501X0 This connects the turbo and the intercooler 2 Throttle body junction pipe Current parts are combined with the throttle body inlet elbow 17 and look different 28 Air filter All FMIIs and 94 05 Voodoo kits 05 16060 90 93 Voodoo kits 05 16070 29 Water line Bag 3X 22 8001 This will need to be cut into two pieces as there are two lines in and out for the turbo 30 Air filter mount pipe 22 40210 FMII kits only not included in Voodoo kits as the MAF AFM takes its place 31 Check valve 36 90010 This is used for the vacuum lines going into the charcoal canister and the cruise control 32 Constant torque hose clamp These have four washers stacked underneath the hex that s used to tighten the clamp These hose clamps are tight when the four washers bottom out on each other it s important that the clamps aren t tightened beyond this point 33 Winzer hose clamps There are more basic and have a blue collar over the tightening screw 34 T bolt
24. 6 constant torque hose clamp 36 70040 This hose is the 90 elbow with a built in hose it may also have an aluminum bung The hose will have a longer straight section on one end this end connects to the compressor The clamp can be snugged but leave it loose enough to allow ro tation about the compressor You may have to trim a little bit off the turbo side do so if the inlet doesn t line up with the airbox Flyin Miata 30 Rev 6 3 970 464 5600 T 10 Flyin Miata If you chose to recirculate the BOV the Voodoo kits must have their BOVs recirculated follow this step If you chose to vent your BOV to the atmosphere VTA skip this step Plumb the 3 4 hose from the outlet on the BOV to the aluminum bung on the compressor inlet hose 22 50405 The hose typically goes down towards the sway bar then back up towards the compressor inlet hose This hose can be routed differently if you d like but be sure that there are no kinks Attach the hose in a few places with the included tie wraps but don t get them so tight that hose is crimped A hose clamp will be required on both ends of this hose Support the alumi num elbow while you re installing the hose to ensure it doesn t become unglued If it does be come unglued reseal it with some silicone sealant Do NOT re orient this aluminum elbow On Voodoo cars it s very important for the outlet inside the hose to point towards the turbo any other orientation will cause idle pr
25. agement systems we d be happy to help e Be kind to your transmission and differential The stock transmission and differential have proven reliable in turbo charged cars provided mechanical empathy is exercised This means no smoky burnouts from a standing stop and no speed shifting e Don t use header wrap as it causes the manifold to crack Using header wrap will void your war ranty e f your car accelerates slowly but revs quickly you ve overwhelmed your clutch time for a better one Our Level clutch is economical has very friendly behavior and holds a lot of torque 318 ft lbs We may be biased but we strongly recommend it e The silicone hoses can be cleaned with ethyl alcohol Rubber treatments will rejuvenate the out side Section 23 Maintenance e Engine oil change interval for mineral base oils is 2500 miles Synthetic base oils may extend the interval to 5000 miles The synthetic oils are strongly recommended cheap non synthetic oils are false economy No really ask the guy who had to replace his turbo We typically use Redline 10W40 We like to change the oil once the dipstick is no longer visible through the oil on it when you re checking the level Check the condition regularly until you get a feel for how quickly your car dirties its oil Bear in mind that hard use such as track use will wear out the oil faster Oil catch cans air oil separators that DON T drain to the oil pan can improve the he
26. alth of your oil and future health of your engine They can possibly extend your oil change intervals but pay attention and be conser vative e f you got the hard line kit you shouldn t need to ever worry about the water or oil lines running to the turbo The standard silicone rubber water lines and oil drain should last multiple years but they won t last forever Briefly check them at each oil change for any weeping cracking brittleness You can find generic replacements locally but our parts are much higher quality and will last longer If you do want to source them elsewhere you ll need 66 of 5 16 line preferably silicone for the water lines and 20 of 5 8 rubber not silicone for the oil drain Our part numbers are 36 40120 for the water line and 36 40231 for the oil drain Flyin Miata 46 Rev 6 3 970 464 5600 e The air filter needs to be cleaned as necessary there isn t a specific mileage requirement it sim ply needs to be cleaned when it s dirty It s an S amp B filter so you should clean it using their kit You should be able to use a K amp N kit if need be but be sure not to over oil the filter All FMIIs and 94 97 Voodoo and Voodoo II kits use filter 05 16060 The 90 93 Voodoo and Voodoo II kits use filter 05 16070 e The blow off bypass valve will need to be cleaned occasionally If it seems to be making more noise and or making noise on a gradual throttle closing where it didn t make noise before it prob
27. apart and see what has happened If one or more of the injectors won t spin chances are one of the O rings was unseated and is binding Fix this replace the O rings if they re damaged and reinstall everything 5 99 05 cars only Reinstall the top half of the intake manifold 6 You ll need to verify that your installation is leak free but that shouldn t happen until the ECU has been installed The steps to check for leaks is later in these instructions If the ECU is in now you can check for leaks now following those steps 7 Tighten down the gas cap reconnect the relay and turn the car on but DO NOT start it Jump a paperclip works well Gnd and F P in the Diagnosis box in order to keep the fuel pump on This ensures that the system is fully primed Leave the jumper connected for 5 10 seconds then re move it Once the fuel system is primed check all of your connections and be sure that there are absolutely no leaks Check all of the junctions where the fuel injectors seat into the fuel rail Flyin Miata 26 Rev 6 3 970 464 5600 8 90 97 Cars Only Once certain that there are no leaks pinch off the rubber return line the line coming off the FPR bolted to the fuel rail going to the forward of the two hard lines at the frame and check again for fuel leaks Be sure that whatever you re using to pinch the line won t damage it This increases the fuel pressure to the maximum so you ll
28. aster lhe a are legdi Ha IC saival r AH filling Le ths suo doje IMG compre f grd nar ilportirg PR e ilh par ea Me I ELERI o a fi aj paning Ci aard Flyin Miata 13 Rev 6 3 970 464 5600 Section 5b Oil Supply for 96 05 Cars Bag to use 4B The oil supply system is the lifeblood of the turbo When running the oil supply line make sure that there aren t any sharp bends and it is clear of heat sources The oil supply will tap into the oil galley at the oil pressure sensor located under the intake manifold between cylinders 2 8 3 above the oil filter Alternatively if our oil filter relocation kit is installed on the car that can be used as an oil source Our oil filter relocation system does make sourcing the oil quite a bit easier on a 96 05 Follow the directions included with the relocation kit Regardless of what you use as a source do NOT use teflon tape on any of the oil lines or fuel lines for that matter A small piece could get into the oil passages and clog them which is definitely a bad thing 1 Remove the oil pressure sensor using a 15 16 socket 2 Put the 1 8NPT tee in a vice and attach the oil Factory c pressure sender i MN Union 26 80 16 fitting 36 50200 The side without the internal a chamfer bevel goes into the block the side with Brass T the chamfer bevel goes into the tee The slight 38 501 90 ly 020 larger diameter side goes into the tee if you need a doubl
29. at would not tolerate damage Flyin Miata 21 Rev 6 3 970 464 5600 Section 9 Water Lines Bag to use 3A 7A 7B The Garrett turbo is water cooled and oil cooled This is the reason it will live well past 100 000 miles with modest care The water for the turbo will be picked up at the front of the engine The specific routing we suggest is just that a suggestion As long as water goes into and out of the turbo without the lines rubbing on anything or being too close to a heat source the goal is accomplished There is not a specific in and out on the turbo For the standard silicone hoses see the instructions below For the optional hard lines see their separate instruction sheet 1 Under the thermostat housing remove the small water hose that connects the thermostat housing to the small connection about six inches below 2 Connect the outboard fitting to the turbo Tighten it with the banjo fitting pointing straight down 3 Route the inboard turbo water line to the upper hose fitting on the thermostat housing The wa ter line will need to go above the new coolant hose and over the power steering pump mounting bracket Secure with a 3 8 clamp 3836 70202 4 Route the outboard turbo water line to the lower water hose connection Again the water line will need to go above the new coolant hose and over the power steering pump mounting bracket Se cure with a 3 8 clamp 36 70202 Be sure both lines are far enough away from the
30. be able to check for leaks in the situation most likely t to create leaks 99 05 cars run at a constant fuel pressure and don t have a return line Once you re satisfied that there are no leaks remove what ever you were using to pinch off the return line Do NOT leave the return line pinched while the car is running 9 It s also a good idea to check for vacuum leaks where the injector seats into the manifold head To do this spray carb cleaner at the seat of the injector while the car is idling and listen very closely to the idle of the car If it stumbles even a little bit it means that the engine has sucked in carb cleaner which therefore means that there s a vacuum leak Be sure that you can repeat this behavior before deciding that you have a vacuum leak Chances are that the cause of this is that your injector seats are dried out and hard You can get new ones from Mazda or you can get two Ford fuel injector O rings per one Mazda injector the Ford O rings should be stacked to equal the Mazda injector seat These can be picked up at an auto parts store Bring the original injector seat with you so that you can compare sizes Flyin Miata 27 Rev 6 3 970 464 5600 Section 13 Intercooler Tubes Bags to use 6A The silicone hoses used in the kit greatly simplify installation As they are flexible they can be bent around things while installing them However once they are installed they should not have to be bent Also mak
31. belts 5 90 95 Cars Only Tie wrap the oil feed line to the outer water line right at the turbo to keep the oil line away from the inner fender Make sure there is a piece of rubber hose over the stainless line to protect the water hose opar water ne we pick Jp point Lower water ne pick up point Flyin Miata 22 Rev 6 3 970 464 5600 Section 10 Mount Intercooler Bags to use 6A 1 The inside of the intercooler needs to be cleaned out Seal off one end of the intercooler and pour some mineral spirits into it Seal off the second end and shake the intercooler trying to get the mineral spirits all over the inside Once satisfied pour the mineral spirits out and dry out the inside with compressed air If there isn t any compressed air available let it air dry 2 Mount the flat bracket with Flyin Miata engraved on it 22 31001 to the intercooler using the shorter bolts 36 10420 The bracket needs to be mounted so that the name can be read from the front of the car There isn t a specific front or back to the intercooler mount the bracket based on whether or not you want the FM logo to be displayed The two outside holes are slotted to allow the location of the intercooler to be moved somewhat Use a washer 36 30130 under each nut 36 20120 and bolt 36 10421 3 Mount the remaining two brackets 22 31000 as shown according to the year of your car Flyin Miata 23 Rev 6 3 970 464 5600 4 99
32. cess before the assembly is mounted Once both water lines have been secured to the bracket the outboard line will need to be pulled off of the turbo Leave the line on the banjo fitting and remove the banjo fitting from the turbo don t lose the washers While slipping the turbo assembly into position be sure that this water line is still accessible 6 Big GT3071R and Small GT2554R Turbos Route the water lines cleanly being sure to keep them away from any heat sources or objects that could rub on them There is no bracket included with these turbos 7 Install the studs 36 10331 in the outlet using the methods outlined in steps one and two of Sec tion 6 _ y 8 Remove the rags from the exhaust ports am 9 Be sure that the tab on the heater bypass tube the metal tube running underneath the exhaust ports is not on the exhaust stud The proper order here is head manifold tab nut although it s easy to get the tab between the manifold and head head tab manifold nut This makes the ex haust very loud so if your car is louder than it should be and the noise is coming from the exhaust manifold check the tab 10 Install the exhaust manifold turbo and outlet casting as sembly onto the engine FMIIR kits can leave the external wastegate off for now but you should seal the hole Use the new gasket 06 90300 between head and manifold NOTE If the assembly won t fit between the head and the b frame slot tha
33. creased air density increases the boost level In order to install the washers you ll first need to remove the C clip that holds the wastegate actuator to the wastegate Be careful with the C clip as they re very easy to lose You should hold a magnet next to the C clip as youre removing it otherwise you re likely to lose it Keep in mind that this is something of a trial and er ror procedure If adding one washer doesn t produce enough boost add another one again to each bolt Increasing the boost should be done in conjunction with tuning the fuel so that you can be sure you have the capability to fuel the increased boost Flyin Miata 44 970 464 5600 6 Large GT3071R Turbo only The wastegate actuator can be adjusted between roughly 5 9 psi again this can vary based on a number of factors If the boost is too high the wastegate actuator needs to be lengthened unscrewed if it s too low the actuator needs to be shortened screwed in Keep in mind that it doesn t have to be exact especially if you re using an external boost controller In this situation you d simply be looking for a fair amount of preload on the waste gate actuator which should already be there as that s how we adjust them here The rest of the adjustment would be achieved with your external boost controller Do not extend the wastegate rod so much that there is no preload on the wastegate actuator as this would make the boost build very slowly
34. d Also put rags in the open holes to ensure that nothing accidentally falls down there 3 Remove the bolts that hold the fuel rail in There are small black plastic spacers that these bolts go through they re below the fuel rail These are very easy to lose and very hard to find once lost so be careful with them Gently pull the rail off of the fuel injectors There are also four small black rubber rings that the bottom of the injectors sit in be careful not to lose these either Set the rail out of the way 4 Install the new fuel injectors Be sure to lube the O rings at the top of the injector with motor oil Try not to get any of the oil into the bore of the injector Also be sure that each injector still has its new and included rubber insulator on the base and that the old insulators in the head manifold have been removed These insulators look somewhat like a thick square O ring Slip the rail onto the injectors Be careful here this can be challenging Be sure that each of the injectors is prop erly seated into both the head manifold and rail Also be sure that none of the O rings get moved or pinched Re use the black plastic spacers at the bolts again being sure to not lose them Once everything is properly lined up tighten down the bolts holding the fuel rail down You should be able to turn the injectors although there will be a little resistance If they spin freely or won t spin at all something s wrong Take the assembly
35. do give you a step by step process to follow but problem solving and critical thinking are still required If you have any concerns either discuss the process with us or pay a professional to do the installation We know there are a lot of words in this manual we re sorry but they re all very important words PLEASE READ EVERYTHING Don t skim actually read the entire thing before you start the instal lation We re happy to help but we d rather not read the instruction manual back to you The success of this installation will be determined by a variety of factors The vehicle must be in excellent condition and in proper tune prior to starting the installation Do not attempt to install this kit on a car that is not running properly Before installation fix any problems This will help prevent our kit getting blamed for pre existing conditions Care and attention to detail by the installer are of extreme importance The daily operator of the vehicle must observe all operational guidelines For specific torque values refer to the service manual that s called out in the Tool and Equipment Requirements Use high temp anti seize on any bolts that don t specifically call for other thread treatments Inventory all the components when the kit arrives We strive to ensure all the components are in cluded in the kit but if a part is left out you will want to know it before you are looking for it during the installation Plus this will allow y
36. e C clip they seem to be allergic to humans and like to run away Holding a magnet close is a good idea 5 Bolt the outlet onto the back of the turbo Again you probably won t be able to use a torque wrench here Flyin Miata 15 Rev 6 3 970 464 5600 Section 7 Mount Turbocharger Assembly Bag to use 3A 5A The turbocharger exhaust manifold and turbine outlet casting should now be one piece having been assembled by you or us This complete assembly will be mounted onto the engine The assembly will look like the photo below with the standard oil and water lines If you re us ing our hard lines ignore steps 1 5 and follow the hard line instruc tions Then come back to these instructions and start with step 6 1 GT2554R only Bolt the aluminum adapter 22 60020 onto the com pressor silver half of the turbo outlet 2 Bolt the aluminum adapter 02 70501 onto the bottom of the turbo with the gasket 02 70510 smeared with sealant in between it and the turbo 1 Then thread the hose barb 36 50020 with thread sealant on the threads into the fitting and tighten it 3 Lubricate the inside of the 5 8 oil drain line 36 40231 with grease oil Slide the oil drain hose onto the middle fitting on the bottom of the turbo Cover the top of the hose with larger heat shield sleeve 36 90960 Secure the hose with the 14 2 4mm hose clamp 36 70005 4 Add the water hoses 36 40120 to the turbo The
37. e check The supplied copper washer goes between the fitting and the block not wit grooved sics the fitting and the tee Next add the oil pressure gora into tre block sender as shown to the right Do not use Teflon tape here or anywhere as a small piece of it could find its way into the oil system and plug up an oil passage Instead use a small amount of sealant on the threads no sealant on the first couple of threads though Do not add the union 2 12255 incorrectly labeled as 36 50160 in the picture now as it will be installed after the as sembly is in the block Since these fittings have tapered threads they don t have a specific torque value Make sure they re snug but you ll have to be the torque wrench here 3 Thread this assembly into the en gine block again using sealant on the threads as described above Be sure to thread it into the hole shown in the picture An easy way to be sure you have the right hole without being able to see it is to feel how close it is to the freeze plug When tightening the as sembly make sure the port for the union faces aft Once the assembly is tight thread the adapter 27 12255 into the tee The union needs a small amount of k thread sealant on the union side but not on the hose side 4 Connect the oil supply line 27 32280 to the union and run it up to the top of the engine again NO sealant here Cover the end with a small bag for now Note The intake manifold has been rem
38. e sure that the hoses do not contact anything abrasive particularly anything with a sharp edge When securing the clamps be sure to get the clamp behind the bead that is formed into the pipe 1 Fl There is a longer 19 vs 15 core size not overall length intercooler available for all 01 05 cars and any other Miata without air conditioning If this intercooler was purchased the intercool er out hose may need to be trimmed Hang the intercooler and connect the intercooler in hose but don t connect the intercooler out hose Plumb the intercooler out hose without connecting it to the intercooler then mark how much needs to be cut off It is especially important to not cut too much off here as the hoses are expensive and will not work if they re too short Take a little ata time and be sure of what you re cutting off You can wrap the hose with masking tape to be sure you get a straight edge A razor blade carefully used has proven to be one of the best tools for cutting the hose Weave the compressor outlet hose 22 50100 up from below the car to meet the outlet on the turbo The 2 I D end will connect to the turbo the 2 5 I D p FU TEY end connects to the intercooler If the rear power steering line coming off of the pump is in the way it can be rolled up and out of the way spin it counter clockwise when viewed from the front of the car looking back Use the appropriate T bolt clamps 2 25 at the turbo 36 7
39. ed down loosen the top nut while holding the bottom nut remove both nuts then move on to the next stud Install the studs in the mani fold turbo and outlet 3 Bolt the turbo onto the manifold Don t expect to be able to geta torgue wrench on all of the hardware it won t be possible for most Just make a close approximation of 16 or 24 ft lbs Do get the hardware snug but don t go crazy If you re using Stage 8 hardware 36 00000 tighten the nut then slip the tab onto the nut as shown 2 You want to position it such that if the nut tries to loosen the tabli will interfere with something in the picture you can see that the oi tab will interfere with the turbine housing if the nut loosens be sure to do something similar on all of the nuts Once the tab has been properly positioned snap the E ring into the groove for the nut 4 Now slip the outlet over the studs on the turbo While you re holding that in place move the wastegate arm you ll have to remove the actuator from the arm to ensure that the wastegate door can suf ficiently open it shouldn t catch on the outlet You want it to point not quite straight back when it stops as shown 3 This was an x g BE Ey occasional problem with previous suppliers but not with our current supplier but it s still good to double check Be sure that the face of the end of the wastegate rod is parallel to the face on the wastegate itself 3 Be careful when you remove th
40. ely get slightly hung up before slipping all the way on 13 Connect the 3 8 hose that s built into the compressor inlet hose to the breather on the valve cover 10 No hose clamps are needed on this hose This hose is left long so that it can be routed to a catch can air oil separator if so desired It can be cut short to fit better or left long if you antici pate installing a catch can in the future 14 94 05 Voodoo kits only Route the wires for the airflow meter MAF over to it The 94 97 cars should have the wires come under the lip of the fender around the air box and then connect to the MAF The MAF wires for the 99 05 cars should come through the hole in the airbox wrap tape around the wires to ensure that they won t be cut by the air box If necessary secure the wires to prevent them from chafing on anything Flyin Miata 32 Rev 6 3 970 464 5600 Section 15 Trim Mouth Radiator Inlet Duct 1 90 97 Cars Only First off determine which type of mouth you have If your car has ABS the left side of the mouth should look like the picture on the left with the cutout between the mounting tabs on the side Otherwise both sides should look like the picture on the right If your mouth has the cutout as the mouth below does follow these directions If it does not and the mouth is sym metrical follow the right side directions for both sides Before you start cutting it s usually a good idea to take a
41. er fit Remember if in doubt trim less not more It s a lot easier to take material off than add material back on As with the mouth mark out what you re going to cut before you cut it Try to make sure that your layout looks similar to the layout in the picture The splash pan will al most definitely require additional trimming don t expect it to be right the first time Once the splash pan has been trimmed completely leave it off the car Re install it after your first test drive once youre certain that nothing else will need to be tweaked The splash pan is important for cooling and protection so please don t leave it off Start on the left side first as it s the easiest side to modify Metal shears seem to be the best tool for this job You ll want to start cutting at the front of the pan specifically right where the horizontal and vertical faces intersect Cut up at an angle so that when you get to the second bend on the vertical face the cut is about 1 1 4 off of the horizontal face Once you get to this place cut paral lel to the horizontal face Keep the cut parallel as the horizontal face angles down Continue this to approximately 6 from the front edge then begin to taper the cut up and circle around as in the picture The farthest edge back will be approximately 8 1 4 from the front edge From this point cut straight up to meet the reinforcement at the slot for the sway bar Again this is just a rough place to start from fu
42. ere is a threaded fitting on the back of the silicone throttle body inlet elbow This is for the air temp sensor that s included with FMIIs If you have an FMIl thread the air temp sensor in here If you don t have an FMII i e you have a Voodoo or no electronics kit be sure that there is a plug in this hole This hole is threaded 3 8 NPT which means that the thread is tapered The male and female thread will bottom out against each other before bottoming out on anything visible When tightening this hold the nut on the threaded portion in the silicone hose stationary while threading in the sensor or plug You want to make sure to not damage the bond between the silicone and the fitting If it is damaged reseal it with some silicone sealant 5 Install the throttle body inlet elbow 22 50310 Position everything appropriately On 90 97 cars weave the built in IAC hose onto the IAC valve Once it s in place tighten down the hose clamps You ll have three 2 75 clamps 36 70308 288 to use one at the top of the intercooler outlet hose one at the bottom of the throttle body inlet elbow and one at the throttle body On 90 97 cars only use the 14 27mm hose clamp 36 70005 to hold the IAC hose on the IAC valve 6 Mount the bypass blowoff valve to the throttle body inlet elbow using the built in 1 3 8 silicone hose Hold the valve in place using one of the 33 NU V ME 4 57mm hose clamps 36 70030 Be sure that the outlet on the BOV
43. est drive once you re certain that nothing else will need to be tweaked The splash pan is important for cooling and protection so please don t leave it off Start on the left side first as it s the easiest side to modify Metal shears seem to be the best tool for this job You ll want to start cutting at the front of the pan specifically right where the horizontal and vertical faces intersect Cut up at an angle so that when you get to the second bend on the vertical face the cut is about 1 1 2 off of the horizontal face Once you get to this place cut paral lel to the horizontal face Keep the cut parallel as the horizontal face angles down Continue this to approximately 6 from the front edge then begin to taper the cut up and circle around as in the picture The farthest edge back will be approximately 9 1 2 from the front edge You ll want to stop the current cut and start a new cut that goes straight down following the reinforcement for the sway bar slot Bring the first cut around to meet up with the second cut Again this is just a rough place to start from further trimming will be reguired Refer to the pictures for clarification The oth er side will have to be cut before the pan can be test fit Fl vin Miata 35 Ermy 970 464 5600 3 The right side of the splash pan will reguire two separate cuts The forward cut will be a relatively easy trim while the rear cut will be a little more involved The easiest way to dete
44. he barb The length of the hose is a few inches longer than necessary Flyin Miata 12 Rev 6 3 970 464 5600 Section 5a Oil Supply Line for 90 95 Cars Bag to use 4A The oil supply system is the lifeblood of the turbo When running the oil supply line make sure that there aren t any sharp bends and it is clear of heat sources The oil supply will tap into the oil galley on the left side of the engine block Alternatively if our oil filter relocation kit is installed on the car that can be used as an oil source a longer hose will be reguired contact us Follow the directions included with the relocation kit Regardless of what you use as a source do NOT use teflon tape on any of the oil lines or fuel lines for that matter A small piece could get into the oil passages and clog them which is definitely a bad thing 1 There is an unused oil galley on the left side of the engine block down close to the bell housing Remove the plug This is a 14mm bolthead 2 Install the oil line adapter fitting 27 12365 into the galley at the position shown Use the crush washer 3 Add one of the 90 degree swivels to the fitting 27 12467 Tighten with the swivel pointed forward 4 Attach the braided hose 27 32105 to the fitting and tighten Cover the other end with a small plastic bag and let it hang loose for now ul far the Lhd anes Gil eed filling in he from this Lruzed pad ar the driver s cide nf al pogl walk FE Epo W
45. he bot tom edge of the splash pan Connect the bottom edges of the markings just put down On the rear edge of the slot connect the rear edge of the marking just drawn with the rear edge of the sway bar slot The front edge of the slot should wrap around to meet up with the front edge of the sway bar slot Two half circles will probably need to be cut to clear the mounting bosses on the bottom of the intercooler Mark and cut these after the rest of the pan is complete Again these guide lines are just a rough start further trimming will almost definitely be needed Please look at the pictures to clarify any questions NOTE The forward piece that will be left after trimming will be essentially impossible to fit between the two segments of the intercooler out hose There are two options to remedy this The easiest option is to trim more of the pan off but it s preferable to leave as much of it intact as possible The second option is to remove the intercooler outlet hose from the intercooler install the pan then re install the hose The hose can be difficult to re attach but it is possible On some cars it s easier to put the hose clamp on the intercooler get the hose over the lip of the intercooler then slide the hose clamp onto the hose Finally slide the hose the rest of the way onto the intercooler and tighten down the hose clamp 4 The fender liners may need to be trimmed but it shouldn t be anything too major Once the hoses have been
46. he first rib from the front turns to go under the mouth At that point follow the first rib all the way across the mouth Once you get to the end of the first rib cut vertically at the closest corner between the two vertical faces then connect the two cuts Now cut the vertical face at the end of the first rib Once you get to the next face angle the cut towards the back of the mouth so that it will end where the second rib again from the front terminates at the face you re cutting Cut straight back from that point The arch will be retained but the two arch supports will need to be trimmed The mouth should be test fit at this point The mouth can be close to the hoses but it shouldn t touch them Trim any edges that are too long Flyin Miata 34 Rev 6 3 970 464 5600 Section 16 Trim Splash Pan 90 97 Cars Only 1 Unfortunately trimming the splash pan is not quite as straightforward as trimming the mouth There s more experimentation involved here Remember if in doubt trim less not more It s a lot easier to take material off than add material back on As with the mouth mark out what you re going to cut before you cut it Try to make sure that your layout looks similar to the layout in the picture The splash pan will almost definitely require additional trimming don t expect it to be right the first time Once the splash pan has been trimmed completely leave it off the car Re install it after your first t
47. he turbocharger makes it necessary to slot the frame rail lip on the left side of the car This needs to be a deeper slot than what s described on the previous page Refer to the picture on the previous page to get a general idea of what the slot will look like and to clarify any dimensions specified The turbos we use on the FMIIR are pretty big so you ll need to cut a fairly large slot For this reason we include a weld in plate 22 62000C Please be sure to match our dimensions as closely as possible as this will make our plate fit best Be sure that the exhaust ports are plugged securely we want to keep the metal shavings dust created out of them 1 First you ll want to scribe out your dimensions From where the vertical face that connects to the shock tower would intersect the edge of the frame rail measure 3 8 towards the firewall and make a mark this is the 1 dimension in the picture on the previous page Now measure anoth er 4 1 4 from that mark 4 5 8 from the vertical face and make another one this is the 3 25 dimension in the previous picture Scribe another line that s parallel to the edge of the frame rail and 1 1 4 closer to the left shock tower Make two marks on that line one that s 1 from the orig inal vertical face same as the picture on the previous page and one that s 3 from that mark 4 from the vertical face same as 3 25 dimension in the previous picture Now draw a diagonal line that runs from the marks
48. hose clamps These are pretty tough and are differentiated by the T shape of the bolt that s used The T portion is opposite the nut Flyin Miata 6 Rev 6 3 970 464 5600 w N MO SA Section 2 Disassembly NOTE If you re removing the transmission anyway it s typically easier to install the EGR tube while the transmission is out You should install the turbo at the same time as the EGR needs to be fas tened at both ends exhaust and intake manifolds at the same time na pa cies 1 Remove the dipstick from the dipstick tube You don t need to remove the dipstick tube You won t actually need to do anything with the dipstick but there s a good chance that it could be accidental ly broken during the installation Plug the hole to ensure nothing slips down there 2 Remove the entire intake assembly including the intake snorkel air filter box and the crossover pipe between the MAF AFM and the throttle body The IAC hose won t be reused but also needs to be removed The IAC hose is the small hose that runs from the IAC underneath the throttle body to the crossover pipe 3 90 97 Cars Only Remove the metal bracket that supports the air box from below and the stud in the picture above that locates it on the outboard side 4 90 97 Cars Only If so equipped remove the cruise control unit from the inner fender and re move the gold colored brackets that mount the unit to the car these brackets will
49. ines also now black 8 Gauge pod 21 165XX A dual gauge pod could have been substituted for the single gauge pod 9 Fuel injectors 04 410XX Not included with Voodoo kits the stock injectors are reused there 10 Exhaust clamp and gasket to be used with the new downpipe The gasket is used at the cat 11 Hydra wideband O2 sensor WBO2 06 99150 For use with the Hydra only not included with Voo doo kits The AEM gauge wideband we sell for Voodoo kits has a simlar sensor but other parts are different 12 Exhaust manitold should be black 22 210XX 13 Downpipe 22 46XXX There are two pieces to the downpipe the exhaust clamp holds them togeth er 14 Hydra ECU 07 17000 Included with FMII Hydra kits only not included with Voodoo kits 15 Compressor inlet 22 504XX Current parts look a bit different 16 Blow off bypass valve BOV 05 9012X 17 Throttle body inlet elbow 22 50310 Current parts are combined with the throttle body junction pipe 27 and look different 18 Air box 22 601XX The one pictured is for 99 cars earlier cars will have a different but similiar design 19 Heat shield 02 20560 This is installed over the turbo 20 Turbo 02 70XXX Be aware that because of the shape of some of the bosses that need to be re moved for our purposes some hand grinding needs to be done This can sometimes appear a bit rough but doesn t change the functionality 21 Hydra mounting clip 07 171
50. l without worrying about matching colors Be sure that the exhaust ports are plugged securely we want to keep the metal shavings dust created out of them 1 Cut two slits into the frame rail lip running from right to left passenger side to driver s side up and down on the picture below The slits need to be approximately 5 8 long They need to run up to but not through the face of the frame going straight down If you feel around underneath the edge of the frame rail lip you ll feel the vertical face of the frame rail itself The first cut will be 3 1 4 off of the forward shock tower brace the second cut will be 2 1 4 from the first towards the front of the car or 1 off of the forward shock tower brace For the small GT2554R turbos the slot needs to be longer Instead of making your second cut at 3 1 4 it should be made at 4 1 4 2 Using a hammer beat the tab between the two slits down and out of the way This is a good place to release any pent up anger The farther down you re able to get the tab the better 3 Once the tab is bent out of the way finish the edges and points of the two cuts The smoother the finished slot is the better it looks and the less likely it is to draw blood rut here Flyin Miata 10 Rev 6 3 970 464 5600 Section 3b Slot frame rail lip 3071 FMII and FMIIR kits only If you don t know what a 3071 or FMIIR is this doesn t apply to you The orientation of the compressor on t
51. n sensor WBO2 Wideband Oxygen sensor ECU Electronic Control Unit computer AFM Air Flow Meter 90 93 cars only MAF Mass Air Flow sensor 94 05 cars only MAP Manifold Absolute Pressure sensor standalone ECUs only BOV Blow Off Valve or bypass valve NA 90 97 Miatas NB 99 05 Miatas NPT National Pipe Thread Taper Flyin Miata 4 970 464 5600 Rev 6 3 Section 1 Parts Inventory Below is a picture of all of the parts included in a FMII Hydra Keep in mind that the kit you purchased could be different or newer There s a list of what most of the items are on the following page The parts are listed by the order the appear and are numbered in the picture not necessarily by relation Fiyin Miata 970 464 5600 Serial cable and WBO2 cable For use with the Hydra only not included with Voodoo kits Oil feed line Bag 4X 22 8002X The line for 90 95 cars will be much shorter Intake air temperature sensor 07 47200 serial For use with the Hydra only not included with Voodoo kits 1 1 4 heat sleeve 36 90960 for use with the oil drain hose now black Hydra wiring harness 07 17905 For use with the Hydra only not included with Voodoo kits Boost gauge 23 161X0 This is an old gauge the new gauges look somewhat different 5 8 heat sleeve 36 90970 For use with the water lines It will need to be cut in half as will the wa ter l
52. nd remove the nut The double nut method section 6 step 2 can be used if you have appropriately sized nuts M10x1 25 9 Remove the oxygen O2 sensor from manifold penetrant is a good idea here as well Be careful removing it as it will need to be reused Flyin Miata 7 Rev 6 2 970 464 5600 B 10 Before removing the exhaust manifold zz bend the water bypass tube located beneath the manifold running to the outboard heater hose back toward the firewall as far as possible as shown Use a large prybar prying against the manifold 11 Remove the exhaust manifold Save the nuts they will be reused to mount the cast manifold for the tur bo Plug the exhaust ports with rags 12 Remove the lower splash pan and the black radiator inlet duct mouth The splash pan and mouth will need to be trimmed to fit around the intercooler and reinstalled 13 Remove the bracket from the bellhousing that supported the factory downpipe Re install the bell housing bolts The bracket will not be reused 14 01 05 Cars Only Remove the under car bracing to allow access to the exhaust Pay atten tiong to the different bolt holes in the brace as some are slotted to ease installation Therefore its not necessary to fully remove the nuts on those studs 15 Remove the radiator hose between the lower ouGood tlet in the radiator and the inlet on the block On 90 97 cars there s a metal pipe between two rubber hoses this needs to
53. not be reused Do not disconnect the cable Set the unit in the area below the windshield until we are ready to mount it again 5 Voodoo Kits Only From the air filter box remove the mass air meter MAF air flow meter AFM This is reused on Voodoo kits but not on FMII kits Do not touch the sensing element on the MAF the AFM works with a flap door and isn t as sensitive 6 99 05 Cars Only Remove the intake air temperature sensor and the rubber grommet for the air temperature sensor Remove the plastic divider that holds the two relays Let the relays hang loose for now they will be remounted later 7 Remove the rubber chrome hose that runs from the driver s side of the cam cover to the intake pipe It will not be reinstalled so the two retaining clips bolts can be removed from the front of the cam cover as well 8 Remove the exhaust manifold heat shield These bolts will be old and rusted in place so soak them down with penetrating oil before trying to remove them We don t reuse them so it s not catastrophic if they break After the heat shield is off spray the nuts that hold the manifold to the head and the oxygen sensor with penetrating oil We will be reusing these parts so be careful with them The studs will often come out of the head as opposed to the nuts coming off of the studs If this happens try to remove the nut from the stud Soak in penetrating oil as long as possible then grip the stud at the shoulder a
54. nt Orient everything correctly then start tightening stuff down Use whatever order works but we prefer tightening the bottom of the wastegate pipe to the downpipe then the downpipe to the turbo outlet then the two sides of the wastegate itself then the junction in the wastegate pipe Be sure that you re never pulling anything into position it should all be naturally sitting in the correct posi tion If you pull things into position you ll be replacing broken parts later Flyin Miata 20 Rev 6 3 970 464 5600 Section 8 Oil Lines Bags to use 4A 4B 5A 1 For the standard rubber line route the drain hose down f outboard of the steering shaft and onto the fitting at the sump Secure with a 14 27mm clamp 36 70005 Again this is a tight fit so cursing may be helpful little grease inside the hose will make it go eas er Ensure that the drain hose always travels down hill to prevent pooling and does not interfere with the steering shaft The hose will need to be trimmed for a perfect fit For the optional FM hard drain line see the seperate instruction sheet for details 2 90 95 Cars Only Route the oil supply line 27 32105 up from below the turbo and attach to the swivel fitting on top of the turbo Add the 3 piece of hose 36 40220 around the oil line where it could otherwise rub on the inner edge of the bodywork Retain with a single 8 14mm hose clamp 36 70202 Put a couple of drops of oil on the flare
55. o use 6A 7A A few edges of the air box need to be lined with edge trim 36 90060 to prevent any rattling and to further seal against heat The bottom edge between the two mounting holes the hole for the air filter mounting pipe and the front most vertical edge will all need to be lined If the trim pulls away secure it with a glue such as the silicone sealant in the parts list 90 97 Cars Only Bolt the aluminum air box into place using an M M6 bolt 36 10401 for the up per mount 1 and the M6 bolt 36 10401 under the power steering reservoir 2 for the lower mount Remove all of the black plastic trim that is found on the bottom of the hood around the headlight cut out using the M6 bolt for the rear hole 3 and the M8 bolt sup J plied for the front hole 4 Mount the relays to the air box 5 using the holes in the front of the air box The relays mount to both sides of the air box two on the inside one on the outside box to seal against the hood Gently close the hood and make sure the air box does not interfere with the hood The top of the air box may need to be trimmed to fit under the hood 99 05 Cars Only If the stock computer is retained the OEM air temp sensor will need to be reinstalled Press it into the appropriate hole 6 in the new air box and recon nect the wires to it 6 Attach the compressor inlet hose 22 504XX to the compressor inlet on the turbo with the 52 7
56. oblems The elbow s orientation isn t critical on FMII cars but pointing towards the turbo is still best FMII kits only Attach the air filter mounting pipe 22 40210 stainless steel pipe with laser en graved Flyin Miata to the compressor inlet hose The beaded end should go into the silicone hose Make sure the pipe lines up with the large hole in the air box Use the 59 83 constant torque clamp 36 70050 here As an aesthetic note try to line up the Flyin Miata logo if desired The AFM MAF is not used on any FMIl kits regardless of year Secure the wires for the MAF AFM out of the way as they won t be used either FMIIR kits only The air filter will mount straight to the compressor inlet which is sized appropri ately and reinforced on the end that the filter attaches to 94 05 Voodoo kits only Attach the factory mass airflow sensor MAF 7 to the compressor inlet hose Make sure the MAF lines up with the large hole in the air box Be gentle at this connection i No boost is seen at this connection and if a the clamp is tightened too hard the plas tic could break and be sucked into the turbo Note that the MAF is directional Be sure that the arrow on the side points 3 in the direction of the airflow towards the turbo On 99 05 cars make sure the heavy screen in the airflow meter is toward the air filter 94 97 cars do not have a screen 94 97 cars also need to have the rubber gasket on
57. only 1 The fuel system first needs to have its pres sure relieved First find the relay that s pictured to the side It will be underneath the dash near the steering column It should look similar to the relay in the pic ture but different years had different re lays so it might not be exactly the same Look for a blue wire with a red stripe on a 90 97 car or a red wire with a blue stripe on a 99 05 that s the wire that goes to the fuel pump Start the car and let it idle While the td car is idling unplug the relay This will kill the engine as its no longer being fed the fuel it needs Turn the car off once the engine has stopped The gas cap also needs to be removed to ensure that pressure doesn t build up in the tank Don t reinstall it until the fuel rail is fully installed 2 99 05 cars only The upper intake manifold needs to be removed There are eight 99 00 or seven 01 05 bolts that need to be removed to allow the two pieces to separate Two of these bolts are below the throttle body Be sure to remove any of the hoses and such that will prevent the top half from being lifted off Make a note of where all of the lines go so you re sure to put them back in the right places Once these have been removed tilt the top half forward and out of the way Be careful of the various lines going to the throttle body While they can remain attached you need to make sure that they don t get kinke
58. ou to familiarize yourself with the parts in the turbo kit Prior to starting the installation go through two tanks of the highest octane fuel available Do not dilute with lesser octane fuel already in the tank If necessary drain the tank Using lower octane fuel will result in knock that could damage the engine All left or right directional references are from the driver s viewpoint If clarification of these instruc tions is required please contact us at 970 464 5600 or via e mail at tech flyinmiata com Sugges tions for improvements of these instructions are welcome Please make notes on the instruction set and mail to Flyin Miata 499 35 Rd Palisade CO 81526 These instructions and the operational requirements for this system must be reviewed with the driver Flyin Miata 2 Rev 6 3 970 464 5600 Contents Introduction ee 2 Tool and Equipment Requirement 4 Section 1 Parts Inventory ne 5 Section 2 Disassembly ene T Section 3a Slot frame rail lip small normal turbos 10 Section 3b Slot frame rail lip big turbos 11 Section 4 Oil Return Line 12 Section 5a Oil Supply Line for 90 95 Cars 13 Section Sb Oil Supply for 96 05 Cars 14 Section 6 Assemble Manifold Turbo and Outlet
59. oved for a clearer picture It is not necessary to remove it for installation of the oil fitting Flyin Miata 14 Rev 6 3 970 464 5600 Section 6 Assemble Manifold Turbo and Outlet This only applies to those who haven t opted to have us assemble the manifold turbo and outlet If those pieces are separate in your kit follow these directions If they re assembled ignore this page No gaskets are used between the manifold and turbo turbo and outlet or outlet and downpipe If you use a gasket in any of these locations it will just fail and you ll have to take everything apart to remove it All of our pieces are machined Bt flat the downpipe actually has a slight dome to enhance the _ seal so they will seal once tightened down o 1 All of the non Inconel hardware here should be torqued to 16 ft lbs 190 inch lbs The Inconel studs should be torqued to 24 ft lbs 290 in lbs 2 First install the included studs Be sure that the non Inconel studs 3836 10331 are installed such that the nut will ultimately be installed on the long end The Inconel studs 36 10339 are symmetrical so that s a non issue If you purchased the Inconel studs good call they go into the manifold the stainless studs are used for both s sides of the outlet Use two M8 x 1 25 non locking nuts 36 20240 tightened against each other as a surface for your wrench 1 so that you can tighten them down Once the stud has been tighten
60. r bracket if so equipped See pic ture below For the FM hard oil drain line optional the drain hole location will be determined by the location of the hard line after it and the turbo are mounted but should be very similar See the sepa rate instructions for the hard lines If you have compressed air that you can regulate set the pressure to 5psi and connect a hose to the valve cover breather on the left side of valve cover Drill until the bit just breaks through then up pressure to 10psi Keep the air blowing while you drill and tap the hole DO NOT use pressure over 10psi at any time More pressure will blow the seals out of the engine Be sure to wear eye protection as the aluminum shavings will be blowing out of the oil pan rill the hale fo r the s il drain line F below the moun iing surface 1 The hole needs to be drilled with the supplied 578 edud AU ta ema 37 64 diameter bit It may be easier to start with ek N a smaller drill then work up to the larger bit STOP DRILLING AS SOON AS YOU BREAK THROUGH It is possible to hit the oil pick up tube if you continue through This is not a good thing as it will cause loss of oil pressure A good way to stop the bit from going too far is to wrap the bit with a few layers of masking electrical or duct tape about 1 4 from its end Try to get the drill as straight as possible but it s okay if it s angled slightly It s very important for the tap to go in straight
61. r the boost controller go into further detail here look for the gate m system 3 If you have electronic boost control the default option on the FMII and FMIIR follow the Hydra directions for its installation 4 Non FMIIR kits Only The base boost the boost reached mechanically by the wastegate actuator must be properly set This needs to be done before the heat shield is installed The wastegate actuator should be around 6 psi but will vary based on a number of factors However you might want a different boost level assuming you have the intercooling and fueling to support it It s not possible to get less boost but you can get higher boost but only with an external mechanical manual or electronic boost controller or by adjusting the wastegate actuator Once the car is ready to drive take it out for a spin remember turbos are load driven so you cant set the boost by revving the engine you must drive it Keep a close eye on the boost and watch where it settles If you d like more boost use the appropriate directions 5 Medium GT2560R and small G2554R Turbos Only Add a washer underneath each bolt holding the wastegate actuator to the bracket in the picture they re not increasing the boost 1 The washer will need to be placed between the actuator and the bracket Add one washer to each side at a time until you achieve your target boost Bear in mind that your boost will increase during colder weather as the in
62. reeze as this will cause overheating 70 distilled water 30 antifreeze is usually a good ratio but this will vary based on your particular winter conditions check to be sure you ll be safe Bleeding the coolant is typically easiest to do with the nose of the car as high as possible ds i i ify VEP alk sil ps Flyin Miata 41 Rev 6 3 970 464 5600 6 Once all electronics are installed and the battery has been reconnected you ll need to prime the turbo Remove the main relay 5 there are no clips holding it in a screw driver can be carefully used to help pry it out There s a decent chance you ll break the plastic clips but the relay should stay in place fine without them Crank until you see the oil pressure gauge move Once it moves the tur bo is primed Replace the main relay 7 FMIIR kits only If you have a shock tower brace it may or may not fit with the FMIIR kit since the wastegate sits so high Factory braces can be made to fit but they ll need to be trimmed a fair amount Be sure that you allow a little extra room so there s no contact when the engine rocks 8 Voodoo kits and others with piggyback engine management We often find that cars with piggyback engine management such as the Voodoo box need to have the idle bypass screw backed out a bit to prevent idle droop and stalling If you find that your car is doing this back the screw out one turn at a time until the droop stall goes awa
63. rmine the right shape for both cuts is to use the outside of one of the larger 2 1 2 D intake hoses The bottom edge of the hose should be flush against the bottom edge of the splash pan and the rear edge of the hose should be about 1 1 4 off of the forward edge of the splash pan The cut should ta per out towards the top The edge of this cut that runs along the bottom of the pan should line up with the rear edge of the right most oval hole in the front of the pan The cut should run up to this hole on the right then taper out guickly on the left of the hole The large hose should also be used to mark out the second cut The rear edge of the rear cut will be approximately 5 1 4 off of the rear edge of the splash pan When you re lining up the hose to mark out the cut the bottom edge should be flush with the bottom edge of the splash pan Once that part is marked out move the hose so that the forward edge is 4 3 4 from the rear edge that was just marked This will make the slot 4 3 4 wide at its widest point The bottom edge of the hose should still be flush with the bottom edge of the splash pan Connect the bottom edges of the markings just put down On the rear edge of the slot connect the rear edge of the marking just drawn with the rear edge of the sway bar slot The front edge of the slot should wrap around to meet up with the front edge of the sway bar slot Two half circles will probably need to be cut to clear the mounting bosses on the
64. rther trimming will be required Refer to the pictures for clarification The oth er side will have to be cut before the pan can be test fit Fly in Miata 37 Rev 6 3 970 464 5600 3 The right side of the splash pan will reguire two separate cuts The forward cut will be a relatively easy trim while the rear cut will be a little more involved The easiest way to determine the right shape for both cuts is to use the outside of one of the larger 2 1 2 D intake hoses The bottom edge of the hose should be about 1 below the bottom edge of the splash pan and the rear edge of the hose should be about 3 4 off of the forward edge of the splash pan The cut should taper out towards the top The edge of this cut that runs along the bottom of the pan should line up with the rear edge of the right most oval hole in the front of the pan The cut should run up to this hole on the right then taper out guickly on the left of the hole The large hose should also be used to mark out the second cut The rear edge of the rear cut will be approximately 5 off of the rear edge of the splash pan When you re lining up the hose to mark out the cut the bottom edge should be about 7 8 above the bottom edge of the splash pan Once that part is marked out move the hose so that the forward edge is 3 7 8 from the rear edge that was just marked This will make the slot 3 7 8 wide at its widest point The bottom edge of the hose should be about 3 4 above t
65. s There is a relatively large open area between the frame and subframe which is a good way to get to those nuts The left front wheel can be re moved if you really want easy access However accessing them from below is by far the easiest if you have the proper tools A swivel joint and long 18 extension for your wrench is necessary to access the nuts from below itd be worth the money to get them Once this is done slip the bot tom end of the downpipe on using the clamp NA cars should use the included gasket when con necting to the catalytic converter NB cars retaining the stock post downpipe exhaust should use the stock gasket but NOT the included gasket NB cars using our exhuast should use the included gasket If the exhaust system is on the car tighten all of the connections including the clamp Do this sequentially being sure that nothing is pulled into an unnatural position Otherwise leave the clamp and lock nuts loose and tighten it and the downpipe to turbine outlet nuts once the down pipe has been lined up with the rest of the exhaust Do not tighten anything until the entire exhaust system has been connected and oriented properly If the end of the downpipe is too low or high try rotating the turbo at the manifold If you loosen the nuts there should be enough tolerance between the studs and the holes on the turbo to allow some rotation You might be able to rotate the turbo without loosening all four studs so try just loosening
66. stands x 4 one quart of mineral spirits hammer JB Weld optional eye protection grease funnel long 18 extension optional high temp anti seize oil filter and fresh high quality synthetic oil spray can of cleaning solvent hacksaw hand drill with 72 chuck silicone sealant The Right Stuff is best Loctite blue factory shop manual or equivalent duct tape Penetrating oil PB Blaster is best marker paint pen touch up paint nail polish electrical tape razor blade vise optional universal joint for your ratchet optional Again be sure that the car is running properly and all of the maintenance is up to date Raise the car and support with jack stands NOTE If you re installing new fuel injectors which come with an FMIl go to page 36 to relieve fuel pressure while the car is still in one piece Drain the motor oil Install the new filter NOT the new oil and temporarily reinstall the drain plug DON T OVERSPIN THE TURBO Carefully spinning it by hand is okay but shooting an air nozzle from an air compressor at the impeller isn t The turbo can handle very high rpm with oil pressure i e when the car is running but without oil pressure you will permanently damage the turbo Preliminary 1 2 3 Drain the coolant There is a drain plug in the center of the bottom of the radiator 4 5 Disconnect the battery 6 Acronyms IAC Idle Air Control valve O2 Oxyge
67. t you cut you have two options 1 First you could rock the motor up towards the passenger side This is the easiest method if you have a pry bar and an extra person we suggest you try this method first The easiest way to do this is to put a large pry bar between the power steering pump and the head Flyin Miata 17 Rev 6 3 970 464 5600 valve cover 4 previous page You ll need a helper to pull the motor over as you re installing the turbo assembly Be certain that you re not prying against anything breakable 2 The second option is to lift the motor up You ll need to place a jack under the oil pan to hold the motor up Be sure to use something e g a piece of wood to distribute the load Then loosen the nut holding the driver s side motor mount This is accessed from the outside of the subframe behind the left front wheel Its recessed in a large hole Once the nut has been removed jack the motor up but only enough to slip the turbo assembly onto the studs Once it s on the head lower the motor back down be sure the stud slips back into place and replace the nut This nut should be re torgued to 42 57 ft lbs 11 As the manifold is being placed into position route the oil drain hose behind the AC compressor then forward The water lines should be routed above the new radiator hose they will be located later Once the manifold is on the studs attach the water bypass tube bracket to the exhaust stud as it was originally
68. teering lines and or AC lines to create clearance Flyin Miata 24 Rev 6 3 970 464 5600 Section 11 Re routing coolant Because of the orientation of the compressor outlet the lower coolant outlet plumbing needs to be changed This step should be done in conjunction with Step 2 of Section 13 as the radiator hose and compressor outlet sit very close to each other 1 Using the supplied radiator hose route it from the radiator outlet to the inlet on the block Follow the rough green outline to find the proper routing On some cars and setups the hose fits better if it goes underneath the AC lines not above as they do in the pictures below It should be obvi ous which routing is best for you If the radiator hose hits the compressor outlet hose trim the ra diator hose where it connects to the block Be sure that you don t trim too much but you ll almost definitely need to trim some Use a piece of tape as a guide to ensure a straight cut In a perfect world the hose wouldnt rub on anything but chances are that there will be some contact Try to minimize it and be sure nothing with a sharp edge is rubbing on the hose In those situations a piece of slit hose should be used as a buffer The first picture is from the bottom looking up the second picture is from above looking down Use the included hose clamps 36 70030 48 Aa Flyin Miata 25 Rev 6 3 970 464 5600 Section 12 Install Fuel Injectors FMIl and FMIIR
69. two or three at first The fourth nut is very challenging to get to Asmall difference in the orientation at the turbo can equate to a rela tively large difference at the end of the downpipe so it s a good place to start if things aren t fitting exactly right 17 Install the factory O2 sensor in the open hole closest to the outlet casting Be sure to use an ti seize on the threads Disconnect the factory narrowband O2 sensor wire from its anchor at the bell housing spacer plate if necessary Be sure that the wires are clear of any heat sources The second hole closest to the catalytic converter will be used for the wideband O2 sensor If you dont have a wideband to install be sure to install the provided plug If you don t you ll have a pretty obvious and noisy exhaust leak Downpipe and wastegate pipe installation for FMIIR kits only 1 This is not going to be the easiest part of this installation We re trying to fit a lot of large parts ina small space so it s going to be tight Everything will fit but it s going to be frustrating to get it all in there properly That having been said Flyin Miata 19 Rev 6 3 970 464 5600 2 Assemble the two halves of the wastegate pipe 22 4625X No gasket is used here Be sure to get the correct orientation the piece with the flex coupling is on the bottom the shorter piece is on top The bottom outlet should point down and towards the back of the car the top inlet should point straight to
70. vement of the tube The bracket at the back of the head is not a very critical one but it is very difficult to access This bracket can be left off if de sired 99 00 cars will reuse the stock EGR tube the remaining cars will have a new EGR tube included in the kit 90 93 cars do not have an EGR tube If a new EGR tube is used there s an easier way to install it Once the EGR tube is be hind the head slip the flange over the studs on the intake manifold Then start to thread the fitting into E the exhaust manifold Be sure that the threads are not going in sideways as it might be difficult to thread in properly Once the threads are started be sure that the flange on the intake manifold will sit flat If not carefully tweak the tube as needed Once everything is properly oriented install the nuts on the studs holding the flange to the intake manifold Once all of the threads have been started tighten everything down Be sure to re attach any grounding straps that may have been removed Also be sure that the heater hoses don t touch the EGR pipe shorten them if need be Be very careful removing the heater hoses the metal pipes that they re attached to are very fragile we typically cut the hose off instead of trying to pull it off If you only cut the portion on the pipe you ll be able to shorten the hose and reinstall Flyin Miata 18 Rev 6 3 970 464 5600 15 94 05 cars FMII and FMIIR kits only EGR plugs
71. wards the front Do not tighten this junction just loosely assemble it for now 3 Hold the downpipe 22 4010X and loosely assembled wastegate pipe together with the wastegate pipe on the correct side of the downpipe Slip these two pieces up into the car together from the bottom This will take some patience and twisting and turning but they ll fit Once they re in the right general location make sure they won t fall out don t install any nuts yet 4 Slip the wastegate 02 70580 onto the turbo and install the clamp at the turbo Tighten it enough so that it won t fall off but it should allow some rotation Be sure that you get the clamp properly oriented 5 Start the nuts on the downpipe Don t tighten them yet You ll be calling us names as you install the inner most nut but it is do able Be patient take your time and try different hand wrench positions 6 Connect the bottom of the wastegate pipe to the inlet on the downpipe Slip the collar down and tighten it a bit but be sure it will still allow some rotation 7 Connect the other end of the wastegate pipe to the wastegate Again install the collar but allow some rotation 8 Install the rest of the exhaust as well as the exhaust brace 06 9757X not included with the kit but you should ve picked one up if you re using our exhaust Get the exhaust brace fairly snug let it define the orientation for the rest but leave it loose enough to allow for some moveme
72. y Be sure that you re adjusting the idle bypass screw 6 NOT the throttle stop 7 small set screw and nut on the rotating the throttle mechanism The throttle stop is set from the factory and should never be adjusted A 99 throttle body is shown but they re all similar Also the black goop inside the throttle body where the throt tle plate sits in its closed position is intentional and helps seal the throttle plate Do NOT clean it off Flyin Miata 42 Rev 6 3 970 464 5600 Section 19 Heat Shield 1 Once the base boost is set the heat shield needs to be installed This is a fairly straightforward in stallation The heat shield mounts in three locations using the included bolts Two of these places are on the body 6 and 7 one comes off of the brake booster Bear in mind that the FMIIR heat shield looks different although it mounts the same 2 The bolt that arrow six refers to is out of view in the overall picture Refer to the pictures for the locations Be sure that the heater hoses and turbo oil line don t contact the heat shield as the heat shield will rub through these fairly quickly Also be sure to reattach the ground strap at the back of the heat shield Be sure that the oil line does not rub on the heat shield Secure the oil line if necessary Flyin Miata 43 Rev6 3 970 464 5600 Section 20 Boost Control 1 Connect a vacuum line from the compressor housing 3 to the wastegate actuator 4 Be ab

Instructions - Flyin` Miata

Contents

Download Pdf Manuals

Related Search

Related Contents