Installing My intake setup.(Long)
 

Hey all as you may know I bought a setup for my 89 TII off of ebay. The parts so far that I have gotten are the following: Set of twin throttles I beleive 50mm each from EFIHardware, a "Simply Maz" LIM, Two stainless steel fuel rails, One throttle cable bracket, one throttle stop, one cable pull, and two Pro series 'Ram Tubes'. If I would have purchased all of this stuff retail it would have run me around 800 dollars plus shipping but I really got lucky that one guy had these used and on ebay for an awesome price! I payed a total or 565 USD shipped to my door. Tonight I wanted to do a mockup of the installation to give myself an idea of what I am going to be looking at for fitment issues and other important problems with this intake setup which I have run into after doing this. Hopefully this helps all of you that are planning to buy this setup in the near future to understand what is involved with converting to this particular setup. First I need to try and organize my thoughts on what I have just done and break them down into sections for the thread....ok.....here goes: I will have a pre-install thoughts section, installation notes section, and post installation thoughts section. At the very end I will have some pictures of the instalation process.


Pre-instalation thoughts

From when I got the box to when I opened it and unwrapped all the separate parts I was thinking wow this stuff looks great for "used" parts, even though the buy on ebay said they were basically new. There were only minor scratches, dings, and other small defects but I guess thats to be expected after being shipped accross a large state like texas. At first I was just amazed at how goo all this is going to look on my car and all that and then I started to look over all the parts and it seems that they should flow better than the stock intake manifold as they look like they were designed to be high flowing right out of the box. I also had my first glimps of a D-hole Type TPS which prior to this I had never seen but planned on using one for my Microtech anyhow. On to the installation notes and the pics......




Installation Notes/Picture section

First thing I had to do was take off the stock intake. Due to my previous work on my TII I had already removed the stock TB and the UIM about two days earlier. I also started with the MOP removal and blocking off since I am a big supporter and fan of pre-mix. I forgot that to remove the stock LIM I had to remove the Stock turbo and its manifold. 25 minutes later and several nuts and bolts removed I had removed the stock turbo, a pig of a snail if I do say so but maybe I am just a skinny weakling. Another thing to note is that the aftermarket LIM was somewhat obstructed by the stock S5 Turbo manifold which is another reason I removed it.

After cleaning off the engine block mating surface with a towel I picked up the new "Simply Maz" LIM and proceded to slide it onto the two studs on the engine block. Well to my surprise it didn't slide flush uh oh.....after looking around for obstructions and small rodents lurking between my LIM and my prized 13BT I noticed that one bolt was a little too close to the edge of the LIM's casting :mad: This bolt is one of two that is used to secure one of the small plates that covers one of several gaps between the outer part of the bell housing and the engine block. Well since this is only for mock-up purposes I took my 10mm wrench and took out that bolt. Wala! the LIM slid right on! Ok problem number two noted! Grind a notch for that bolt onto the LIM casting!! Now I took the two nuts for the studs and hand threaded them and only tightened them by hand as I won't be running the engine just yet
http://www.aztechrotary.com/files/ti...ckup%20001.jpg

Ok now we have the LIM bolted onto the engine block. Yay! *victory dance* But wait!....uh oh.....You kow how the stock turbo is both oil and water cooled? Hmmm...where is the provission for the water passage on the stock LIM on the new one well you guessed it, there isn't any!! :mad: It looks like we will either have to fabricate a new water return and plug the old one OR make it so the after market LIM has a fitting for the stock turbo's water return. Well for my setup I will not be using the stock turbo so I will choose to block it off and find another source of water return should my upgraded turbo be water cooled.

Ok problems one and two noted we can move on! :cool:
Now I go and pic up the twin throttles along with the tps and all the throttle linkages. I noted that the bolts they included with the kit are 13mm which is rather an odd size given more of the nuts and bolts on FC's are 10-12-14mm's but that doesn't really bother me. You should have an open end wrench for these ass they are too close to the round part ot the throttles to be able to use a socket or the closed end of the wrench. Here is a pic of the TB's on the LIM sorry about the low light but my other pic was too blury.

http://www.aztechrotary.com/files/ti...ckup%20003.jpg

The next step is the one where I bolt on what goes after the TB's or rather on top of them. Please pay special attention as what I install on the TBs in this procedure is NOT I repeat NOT for a Turbo application but for a Naturally aspirated application. They are called "Ram Tubes". The proper part to be installed into my car is a "turbo Plenum" which is basically what connects the IC piping to the throttle bodies. I liked how they used hex screws to attatch the Ram Tubes which gives it a slightly better over all look if your going for that "show car" look. I just thought it was nice because its harder for people to steal your Ram Tudes :D On a side note the tubes that were included in my setup are the "Pro" series tubes which are longer than conventional tubes and also larger in diamiter. This is for custimizing them to your own spec's. The can be shortened by a certain length to fit different runner length depending on what is better suited for your individual application. Here is a pic of the Ram Tubes on my car. After that one I also included a picture of a "turbo plenum" so you all can see what I will be using when the project is done.


http://www.aztechrotary.com/files/ti...ckup%20005.jpg
http://www.tweakit.net/throttle_body...kel_plenum.jpg

More soon......

Man that looks good vroooom vrooom

Ok as I continue I remember that I don't have my 550's anymore since I am going to be running larger injectors with my upgraded turbo. :) But what will I use to fit the fuel rails on? *sobs*...*idea!* I recall having a set of S5 460's from a deal I made with a forum member last year. Weeee!I run inside and picup the box I had them in and run back outside. :-D I grab one fuel injector out of the box and place it in one of the injector bosses. Hrmm.... It doesn't seem to fit snugly :-/ Wait! they don't need to have the lower 'grommets' so I wiggle the little grommets off of them and wala! they fit lite a charm. Here is a pic so you all can see how they fit in further than they do on the stock Mazda LIM

http://www.aztechrotary.com/files/ti...ckup%20007.jpg

Ok so all the four injectors are on! now to get the fuel rails and place them on the injectors and bolt them down. :-] Well they fit good and don't look like they will leak but the top grommet doesn't touch the bottom of the rail's injector bung. This may lead to problems but I can't say for sure yet. Again the bolt is a 13mm SS unit with a pressure washer to keep the fuel rail from becoming loose. I was able to use a 13mm socket for these bolts though. Included are some pictures of the two fuel rails.
http://www.aztechrotary.com/files/ti...ckup%20009.jpg

http://www.aztechrotary.com/files/ti...ckup%20010.jpg

http://www.aztechrotary.com/files/ti...ckup%20011.jpg


Okie! Now that this is out of the way I took note that I will no longer have the ability to use the stock fuel pressure regulator! therefore I need to add to the list of things to buy an aftermarket fuel regulator as the fuel system will not work properly without a fuel regulator!

Ok now! whats left to do? well I don't have the throttle cable hooked up so lets get to it! Lright the kit came with a cable pull which allows you to use a standard throttle cable and I also have a throttle cable bracket which we have seen in previous pictures on the passenger's side fuel rail in blue anodized aluminum! :-D


Pics of the throttle cable setup in the next post.....

Ok here are the pictures of the "cable pull", throttle cable bracket, and some pics of the stock cable positioned onto the throttle linkages:


http://www.aztechrotary.com/files/ti.../EFI%20006.jpg

Cable pull

http://www.aztechrotary.com/files/ti...ckup%20016.jpg
http://www.aztechrotary.com/files/ti...ckup%20019.jpg

Cable on the pull mechanism

http://www.aztechrotary.com/files/ti...ckup%20018.jpg

Trying to hold the cable up on the bracket

http://www.aztechrotary.com/files/ti...ckup%20015.jpg

I could not get the cable to stay taught enough to hold itself on the bracket so I will have to make a custom bracket to hold the cable on right.

One thing to notice is the adjustability of the cable pull. This isn't just some ghetto rigged setup. You can adjust the position where it stops and the degree to which the throttles are open at idle.

My final installation notes are as follows: I still need to get a tap and die set to make vaccume nipples for the various things that are operated via vacuume/boost to function properly. I also have to run a new set of fuel hoses to the fuel rails along with the new fuel reg that will be required.



Post Installation thoughts


Over all I am happy I am going through with this setup for my car as I want to try new things for myself and not take peoples word for it and all that. But this isn't a project for the people with low budgets nor is it for the people with the intent of having htis on their daily driven N/a. Mainly because it IS REQUIRED that you use an aftermarket engine management system along with all the other fuel system modifications that you need to do to even have this working at all. I would say that you need atleast around 3 thousand dollars to complete this conversion the proper way and buying all the parts from retailers. If you are able to score used parts like I did that price may be around 2k or a little more. But if your the kind that counts pony per dollar this probably isn't for you. I can't wait to finish this car!


Santiago

PS- I hope you all enjoyed the journey so far. Comments and questions are more than welcome. :)

SWEET. i cant wait till its done either... i wanna see some numbers, as you are inspiring me! do you have any idea what kind of gains you will get out of it?

Not a single clue! :D But like I said this isn't for the people on a budget. I am going to take my time with this car and turn it into a monster that preys on vipers and such. :cool: I am going to love their looks in the mirror. *grin* The car most likely won't be streetable untill this summer when I get to tunning the Microtech and rebuilding the engine.(right now it smokes more than a pot-head)


Santiago

talk about TRUE ENTHUSIAST!

I forgot the "money shots " :D

http://www.aztechrotary.com/files/ti...ckup%20012.jpg

http://www.aztechrotary.com/files/ti...ckup%20013.jpg


:D :D :D

looks sweet man....but dont worry i too will soon have mine....:)

Looks great, that would be so loud running with just the stacks....



-Jacob

Once my engine has been street ported and rebuilt I will be running the car N/a with this setup so that nothing see's boost untill after a good 1500 or 2k miles. Then I'll slap on the turbo and run with it. :D

im confused, what exactly does this provide with the dual tb's and such?

WEll the IDA manifold and dual TB's flow a lot more than the stock manifold.
Hell with really agressive street ports and IDA carbs, ppl are getting 200hp at the wheels on N/A's.
Damnit 1987, you beat me too it, lol :D But I am going to run an IDA intake on this, but I am going to make some bent 50mm pipes to turn it into a DCOE sytle set-up with a custom intercooler.
Keep us updated.

I'm guessing low gas milage = more HP and more boost since more fuel will be avaliable to burn = more HP...am I wrong?

You must have ALOT of FREE time in your hands....If I remember correctly you just got that a few days ago...That is an awsome setup :worship:

Looks like fun, Mr. Powah.

This is great I just got ahold of a friend of J-rat's that I think can make a custom turbo plenum for me :D

so let me get this striat. you spent over $2k to DOWNGRADE from 3 45mm butterflies to 2 50mm. thats roughly a 18% drop in cross sectional area. HUH?

man you ARE hell bent on being unique.

Looks like its coming along nice.Good luck through your progression.

what filters the air?

i give you props santiago. it looks good to me, and i can't wait to see what it does when it's boosted. although it will suck running it n/a for awhile since you have low comp rotors.

Yeah it will suck without boost TII's are slow pigs.

for n/a applications they sell a filter kit

I haven't seen any dynosheets or info from anyone running that setup n/a. Do you have a link that has it?

The setup certain looks cool, it's too bad you can't have the velocity stacks at the end...

I'd rather have the IC hooked up. ;)

Wow, looks like that engine bay could use a wipe down.