New 2011 Mazda2 Turbo Build

Co.CarSpotter

Member
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Mazda 2 Sport
Hey Everyone! It's been a long time since I've posted on here, but over the last year (almost exactly 1 year) I've been working on and off turboing my M2.

I want to preface this in saying that I don't have any formal automotive training (never even took an automotive class in High school) but I wanted to jam a turbo in my car, and I had alot of help from my brother, who is a professional welder. We finally finished the build portion of it on July 18th, I started around July 20th 2017.

Being that I had no experience, and am currently in College, this build took much longer than I had hoped it would. But I hope, if someone else is determined enough to also try this, they can at least learn from my many mistakes.

I'm not entirely sure how I'm going to organize and write this out, but I guess I'll just roll with it as we go.

I'll also provide links to resources that I used at the bottom of this first post.

My Goal

My Goal for the car was to just make a bit more power, ~160hp. Nothing crazy, but just some more power, so I could get up the mountain roads I drive a bit faster.

Reasearch

The Physical Build took about 1 year of working on and off on my car. But in reality the build goes back several years, When I saw AN7's Mazda 2 Turbo Build. He made it look very doable, so I began to research. I don't really have to go into this, because it's super mundane and self explanitory, but what it boils down too is learning how engines and turbos work, figuring out the specifications of the Mazda 2, figuring out what the Mazda 2 already has from the factory and what I need to add, building up enough money to buy the required parts, and then buying all of the required parts.

The Build

This is what the majority of this write up is going to consist of, so lets get into it.

I began by taking my car apart. I initially did this without any sort of service manual, and a few days in, I didn't know how to get the exhaust manifold out. So I subscribed to Chiltondiy's Mazda 2 service manual, which ended up being the one most important purchase I made. I used it so frequently and it taught me so much about the Mazda 2 that I don't think it would have been possible for me to have done anything without it.

After I eventually wrestled the exhaust manifold out, I began to try to follow AN7's early build. When he still had the 1.5l in it. I quickly realized that wasn't possible, we weren't able to make an exhaust flange plate. We didn't have access to a cnc plasma cutter, and I wasn't confident enough in myself to get it just right with a plate of steel and a hole saw. What we ended up doing is chopping the stock exhaust manifold and building the new turbo manifold based off of that. It's ugly, and not super high flow, but we did what we could. It took us 5 weeks to make because we didn't have the right tools for the job at the time.

https://flic.kr/p/29dQhfG

https://flic.kr/p/29dQhAw

https://flic.kr/p/27V6gT8

https://flic.kr/p/MahSRw

After that was finally done, we attached the turbo and I quickly realized that the exhaust was not going to go where I wanted it to go, along with the stock wastegate being in the way, which we relocated with a little bracket. After about 20 minutes of staring at my lack of planning, I decided the downpipe was just going to go up and over everything and then down and out the exhaust channel underneath the car. It ended up looking like a rather... interesting part.

https://flic.kr/p/28cEVC3

https://flic.kr/p/29i2mDK

The rest of the exhaust was very easy, we basically just replicated the original one but with 2.5 inch pipe, which is definitely overkill. If I were to do it again, I would use 2 inch pipe or slightly smaller.

https://flic.kr/p/28cEV5j

https://flic.kr/p/28cEUN7

And of course I wrapped all of the "very hot" bits, including the Catalytic Converter in exhaust wrap and heat shield.

https://flic.kr/p/29dQ8Y1

I also made the intake after the turbo manifold was finished, I bought a universal kit, that happened to fit both the turbo inlet, and the engine intake. And I bought an intercooler that fit.

https://flic.kr/p/29dQbgs

https://flic.kr/p/MahPR3

After all of the "physical stuff" was "done" (I had do redo a bunch of stuff on the intake and exhaust side) I was going to wire a Megasquirt 2 in, and bought EVERYTHING to do so and realized that I did not know what I was doing. (so if you're looking for a complete MS2 kit, pm me). I worked a bit with a tuning shop about an hour from me, but realized that it'd be much more cost effective to keep the stock ECU and have Dynotronics tune it.

For this to work, I had to put in the secondary heated O2 sensor, so everything came out once again, and a bung was added a ways down the downpipe. After that the car actually ran. It made STUTUTUTUTU turbo noises, but burned a ton of oil because of it. It also leaked oil like crazy, but I just had to apply some teflon tape to the adapter plate for the turbo. The Turbo drain still backs up a little bit, which I still need to solve, but for now its usable.

At this point, I assumed I could just tune the car with the OEM stuff... I could not. I ended up buying a Deatschwerks fuel pump and Denso 700cc Miata Injectors. (Part #22S-00-0700-4) These are drop in replacements, which is what I wanted, but bought the wrong ones twice, and then finally found the right ones.

Along with the fuel stuff, I also bought a BOV to solve the oil burning issue, a Catch Can, a boost gauge, and a few other things to kind of finish it and polish it up. I also had to buy a new 2 3/4 inch maf tube. This seemed difficult, until I realized that the MAF bolt pattern is the exact same as a Subaru WRX.

I also relocated the Battery to the trunk, so the intake for the turbo had room. If you really want, I can show you that process, but I didn't really take any pictures while I was doing it.

Another thing, the stock MAP sensor was replaces with a GM style 3 bar MAP sensor.

Oh, also, I'm running a blow through turbo setup. (MAF after turbo)

https://flic.kr/p/29i51FT

After figuring that stuff out, It's finally done, and is in the process of getting tuned.

I have to say though, it does currently run and drive. But I wouldn't drive it much being that It doesn't have a tune in it to deal with the excess air and gas going into the engine.

Conclusion

This was difficult, mostly because of my own lack of planning. I am blown away that I actually finished it though and that it runs. If you have any questions please ask away, I'll do my best to answer them. The car is very tight to work in, I recommend removing the engine if you decide to do this, because it'll save you alot of time and frustration.

Some things I forgot to cover in the main thing:

The Cooling for the turbo is provided by the convenient coolant lines from the EGR valve, that was removed.

There weren't many modifications made to the chassis, except for 2 holes drilled for the battery cable and the vacuum line for the boost gauge.

Links and Stuff

AN7's Build: https://www.mazdas247.com/forum/showthread.php?123824858-AN7-s-Mazda-2-1-5-Turbo-Build-Log

ChiltonDIY: http://www.chiltondiy.com/

Electrical Stuff:
https://www.diyautotune.com/?s=3+bar+map
https://www.summitracing.com/parts/sum-g1231-k

Exhaust Bits:
I got all of it from Summit Racing

Other:
Turbo: TD04h
BOV: https://www.summitracing.com/parts/tbs-ts-0982-1003

Fuel Stuff:
Injectors: http://deatschwerks.rpmware.com/deatschwerks/deatschwerks-fuel-injectors/22s0007004/i-411482.aspx
Pump: http://deatschwerks.rpmware.com/dea...ific-intank-fuel-pumps/93010848/i-519999.aspx

Thanks for taking a look, Sorry for the lack of images, I was a little too busy while I was working turboing my car.

I'm working on uploading the images, but for now they're just links. Something was a bit off with uploading them.

If you want more pictures of specific things, or how the stuff fits in place, feel free to ask, and I'll attempt to get a good picture.
 
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