Turbos, Manifolds, Exhausts, EMS Solutions And More! READ

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Outlawstar98

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2003 MazdaSpeed Protege / 2013 BRZ
Turbos, Manifolds, Exhausts, EMS Solutions and More!

THIS IS A WORK IN PROGRESS, PLEASE BE PATIENT WHILE IT GETS MADE. Should be workable in a week or so!

Welcome! In this thread there will be all you need to know for the basis of what we have available and any information that we can supply, to what you can do with the turbo, the exhaust system, the EMS System and More! There will also be a list of what types of parts that are available to buy, and what used to be that is no more. (Discontinued parts)

Index
Post 1: Intro
Post 2: Turbo’s and Related Parts
Post 3: Manifolds
Post 4: Exhausts
Post 5: EMS Solutions
Post 6: Engine Related
 
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Turbo’s And Related


Quicklinks
Stock Turbo Torque Specs!
HOW-TO Replace Wastegate Actuator
HOW-TO Turbo Oil Lines

Most Used Turbo Upgrades (biggest to smallest)
Garrett GT3076R
Proficient up to 25-30psi and up to 450-500 HP, It will bolt up to stock manifold and will require custom oil lines, custom coolant lines and new couplers for the intake. Also will need metal Intercooler piping which if already upgraded it will need to be modified due to different angle of the turbo housing. Will need to transfer the stock wastegate, bracket and modify it to fit properly. I highly suggest upgrading to a stock replacement ATP Wastegate due to it being better built. Turbo will be a TIGHT fit. Need slimfans to run.
Garrett GT3071R
Proficient up to 25-28psi and up to 400-450 HP, It will bolt up to stock manifold and will require custom oil lines, custom coolant lines and new couplers for the intake. Also will need metal Intercooler piping which if already upgraded it will need to be modified due to different angle of the turbo housing. Will need to transfer the stock wastegate, bracket and modify it to fit properly. I highly suggest upgrading to a stock replacement ATP Wastegate due to it being better built. Turbo will be a TIGHT fit. Need slimfans to run.
Garrett GT2871R
Proficient up to 20-25psi and up to 350-400 HP, It will bolt up to stock manifold and will require custom oil lines and new couplers for the intake. Also will need metal Intercooler piping which if already upgraded it will need to be modified due to different angle of the turbo housing. Will need to transfer the stock wastegate, bracket and modify it to fit properly. I highly suggest upgrading to a stock replacement ATP Wastegate due to it being better built. Need slimfans to run.
Garrett GT2860RS Aka’ “Disco Potato”
Proficient up to 18-23 and up to 350-400 HP, It will bolt up to stock manifold and will require custom oil lines and new couplers for the intake. Also will need metal Intercooler piping which if already upgraded it will need to be modified due to different angle of the turbo housing. Will need to transfer the stock wastegate, bracket and modify it to fit properly. I highly suggest upgrading to a stock replacement ATP Wastegate due to it being better built. Need slimfans to run.
Garrett GT25R
OEM Replacement. Depending where you perchance this turbo from it could be OEM or could be directly from Garrett or other cars that use the same size turbo. Depending where you perchance it from differs the ease of install. Directly from Mazda it will be 100% direct fit.

Wastegates
ATP Wastegate Actuator
BEST replacement for the expensive stock wastegate. (6-8 PSI) More PSI wastegates can be obtained from ATP.
HKS Wastegate Actuator
This is a replacement for the stock wastegate, not highly used due to the PSI limits. (11.4-12.8 PSI)
OEM Mazda Wastegate Actuator
Stock OEM replacement, highly Suggest upgrading to the ATP due to the stock Diaphragm is known to go bad sooner than any other. (stock boost level ~6 PSI)
Forge Motorsport Wastegate Actuator
This is a OEM replacement from Forge Motorsports, PSI Varies depending what springs you use. You can change out the spring at any time. LINK
 
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Manifolds

Quicklinks

Stock Replacement Exhaust Manifolds
SteedSpeed Manifold
Still In Production; PICTURE This manifold can be purchased though steedspeed. Made out of 1018 mild steel.
Thunder manifold
Still in Production; PICTURE This manifold can be purchased though Protephile. V1 had issues with cracking, which have been revised with the V2. All new Manifolds sold are V2. Made out of 304 stainless.
Focus Manifold
NO LONGER in Production; PICTURE
MAM Direct Stock Replacement Maifold
NO LONGER in Production; PICTURE


T3/T4 Turbo Manifold
HiBoost Turbo Manifold
NO LONGER in production; PICTURE
MAM Stripper Manifold
NO LONGER in Production PICTURE
MAM Thumper Manifold
NO LONGER in Production; PICTURE
SteedSpeed T3/T4 Manifold
Still In Production; PICTURE This manifold can be purchased though steedspeed. Made out of 1018 mild steel.
 
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Exhausts

Quicklinks


Exhaust Systems
GHL 3" Turbo Back
NO LONGER in Production
ION 3" Turbo Back
NO LONGER in Production PICTURE
Perrin 3" Jpipe back
Catless PICTURE
Vibrant 3" Spipe back
High Flow Cat PICTURE
Corksport 60mm Jpipe back
Choice of Resonator/cats PICTURE
Corksport 80mm Jpipe back
Choice of Resonator/cats PICTURE
Thermal CatBack 3"
PICTURE
Magnaflow Catback 2.25"
PICUTRE
Racing Beat Catback 60mm
PICTURE



Downpipes
P.E.P 3" downpipe
PICTURE 304 Stainless Steel, Replaces S and J Pipe, STOCK replacement GROUP BUY WAS HERE
CorkSport 2.5" Downpipe
PICTURE Older Design was a 2 piece which was later redesigned into a single downpipe. 304 Stainless Steel. Can be Purchased on www.corksport.com
GHL 3" Downpipe
NO LONGER in Production PICTURE
ION 3" Downpipe
NO LONGER in Production PICTURE
SpeedCircuit 2.5" Downpipe
Stainless Steel PICTURE
 
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EMS Solutions

Quicklinks
Stock ECU reflashed? Info Here
AEM F/IC writeup
HALTECH E6X Install Guide
MegaSquirt 2 EMS Install Guide

Standalone Units
Haltech Platinum Sport 2000
Up to 12 Injector Drivers, Up to 12 Low Impedance, Up to 16 High Impedance Injector outputs. Up to 6 Ignition Outputs. Also has 7 Analog, 1 Digital Switched and 3 Digital Pulsed Additional Programmable Inputs. Additional Programmable Outputs include 4 PWM/DPO and up to 9 Digital Outputs. It has VE Tuning, Datalogging up to 200 samples Per Second (laptop or onboard), closed Loop O2 Control, CAN Output ( Supports IQ3 Dash), USB Communication, Internal Map Sensor (2.5 Bar (up to 22 PSI), Real Time Programming Software (uses ECU Manager Software), Plug and Play Options, Adjustable Resolution (Up to 32x32), The Max Map Sensor Range is 10 bar(130 PSI), It also has Closed Loop Boost control and Custom Censor calibrations.
Haltech Platinum Sport 1000
4 Injector Drivers, Up to 8 Low Impedance, Up to 16 High Impedance Injector outputs. Up to 4 Ignition Outputs. Also has 7 Analog, 1 Digital Switched and 3 Digital Pulsed Additional Programmable Inputs. Additional Programmable Outputs include 4 PWM/DPO and up to 5 Digital Outputs. It has VE Tuning, Datalogging up to 200 samples Per Second (laptop or onboard), closed Loop O2 Control, CAN Output ( Supports IQ3 Dash), USB Communication, Internal Map Sensor (2.5 Bar (up to 22 PSI), Real Time Programming Software (uses ECU Manager Software), Plug and Play Options, Adjustable Resolution (Up to 32x32), The Max Map Sensor Range is 10 bar(130 PSI), It also has Closed Loop Boost control and Custom Censor calibrations.
Haltech Platinum Sprint 500
4 Injector Drivers, Up to 8 High Impedance Injector outputs. Up to 4 Ignition Outputs. Also has 1 Analog (for Wideband) Additional Programmable Inputs. Additional Programmable Outputs include 2 Generic Outputs (switched On/Off Only). It has VE Tuning, Datalogging up to 200 samples Per Second (laptop only), closed Loop O2 Control, CAN Output ( Supports IQ3 Dash), USB Communication, Internal Map Sensor (2.5 Bar (up to 22 PSI), Real Time Programming Software (uses ECU Manager Software), DOES NOT HAVE Plug and Play Options, Adjustable Resolution (Up to 32x32), The Max Map Sensor Range is 10 bar(130 PSI), IT DOES NOT HAVE Closed Loop Boost control And finally it does have Custom Censor calibrations.
Haltech E6x
4 Injector Drivers, Up to 8 Low Impedance, Up to 16 High Impedance Injector outputs. Up to 4 Ignition Outputs. Also has 1 Analog, 1 Auxillary and 1 Trim Input Additional Programmable Inputs. Additional Programmable Outputs include 4 PWM/DPO, 2 Digital and 1 Auxillary. Datalogging up to 200 samples Per Second (Laptop Only), closed Loop O2 Control (Narrow Band Sensor), Internal Map Sensor (2.5 Bar (up to 22 PSI), Real Time Programming Software (uses HalwinX Software), Plug and Play Options, Fixed Resolution to 22x32, The Max Map Sensor Range is 7 bar(87 PSI)
AEM Universal EMS
System is fully enabled—Never pay for upgrades! Runs on Windows™ compatible software, Live help window eases tuning process, Free software updates on aempower.com, Fuel table automapping, Programmable traction control, Onboard 512kb datalogger, Up to 10 cylinder sequential fuel injection, 10 independent peak & hold injector drivers, Direct drive ignition feature eliminates need for igniter or ignition module, On-board wideband UEGO controller, 6 general-purpose outputs, 7 definable switch inputs, Electronic boost control, Soft cut rev limiters, Two step launch control, Wet or dry nitrous control, Definable knock control, Full idle control, 4 EGT inputs with fuel control, 16/32 hybrid high speed processor
Megasquirt 2



Piggy-Back Units
AEM F/IC
Unichip
SSAFC (Split Second Air Fuel Controler)
Airflow Logistics AFC
 
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Sources: JDM Sam, TheMAN
Q1: What engines can I use for a direct swap/replacement?

A1:
  • Any FS 2.0L from a 2001-03 Protege or Protege5, manual or automatic does not matter, you're swapping the engine not the transmisson, the flywheel and clutch will bolt up to the crank of the donor engine, just keep all your manual parts and pieces to swap over
  • 1993-1997 MX6/Probe and 2.0L FS engines are available but not recommended because the cranks are not forged, and you will have to take it apart to transfer parts over, and high mileage on these engines.
  • 1993-2002 626 also have 2.0L FS engines but only the 2000-2002 blocks should be used, some 99s depending on the production date. The difference is the crank was reported to be forged in the later year models
Q2: What you must buy new or transfer over on all FS engines?
A2:
  • Main cap support plate, specific to MSP it has the turbo oil drain machined into it and is right above the oil pan.
  • Rear oil cooler, lines, oil filter stud
  • Intake manifold, valve cover, thermostat cover, heater bypass pipes, the coolant junction block, and the bracket around the side of the head above the junction block
  • Rest of your current Protege accessories and manifolds
  • If you use a non Protege cylinder head you MUST transfer the Protege cams, cam gears, valve cover over, crank pulley, ignition. You MUST use a non-distributor cylinder head.
  • 98-99 626 FS have smaller intake ports and have different cams.
  • 2000-2002 626 uses the same cams as Protege
  • Any other brackets or parts that broke as a result of the engine failure
  • Maintenance related parts and hardware. ex. clutch, timing belt, spark plugs, hoses, seals, gaskets, pumps, etc.
  • Good time to do the rear engine mount if yours is torn
  • Your existing transmission and drivetrain parts.
Q3: Can someone show me a how to guide through the entire swap process?
A3:
Stop, step away from the forum, hire a competent mechanic before you **** s*** up even more. (rlaugh) If you are seriously competent and mechanically inclined, the available manuals online should tell you everything you need to know to do it. There is a reason why there are paid professionals in the field. So if you can't RTM and understand the process, this applies to you. This is not a beginner's task. If you want to learn go enroll at a technical school for automotive technology. BTW, shops usually do charge more to fix something a DIY'er ****** up. http://www.floptical.net/mazda/
(RTM)

Q4: Where can I find places that sell engines?
A4:

Salvage yards in your area, if you find one local you wont have to pay to ship a big heavy pallet.
www.google.com

(google)

(info from HERE )
 
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