Fitting a BOV and the FCD

[Brett]

Heres a brief overview of fitting a new BOV and the FCD.
Overview photo:-

[Brett]

As I am planning on running 12+ psi of boost pressure in the near future (and secretly wanted the wooshy sound effects) I deceided to buy a 2nd hand Blitz BOV from ebay. (£76 shipped) The BOV came with a metal turbo to intercooler pipe. (which I am well chuffed with, the standard mazda pipe leaves a lot to be desired in terms of torsional maleability) The pipe to the other control valve is retained, but the 90deg pipe to the old BOV is no longer needed.  I will post a picture tonight of the assembly you are removing, but for now heres what you are putting in, and a few pointers along the way.
TIP:- Work whilst everything is still warm (hot in my case) in the engine bay, this makes removing the old hoses easy and reduces the chacne of you doing any damage.

[Brett]

Make sure you plug the hole in the AFM to turbo pipe, otherwise you will hit a whole load of problems as you will be sucking in unmetered air.

[Brett]

A better view of the new metal pipe.  
NOTE:- This pipe is a bit longer than the one it replaces, this means that although you can get the top 90deg hose on further, it is a bit of a bitch to fit.  I undid the intercooler bolts on top of the UIM this gave me enough movement to get the pipes back on without damaging anything.

[Brett]

A view of the pipe that breaks with no provocation (I did not break it doing the BOV fit BTW, it was broken when I got the car!)

Fitting time from start to finish = 27mins, longer if you include me phoning up Grinder to gloat.

[Brett]

The Knightsports FBCD is an absolute piece of **** to fit. If you cant fit this item then please hand in your V5 and car keys as you leave the 2nd gen section!!   :rollin
Basically the FCD has a plug and a socket on a flying lead. You put the plug into the ECU cable and the socket end goes onto the Pressure sensor. Its totally idiot proof because they are 3 pin plugs that only fit one way round.
Easy mod that stops the ECU cutting fuel to the rear rotor when it detects over boosting. (no such thing, right :bandit)

[grinder]

looks good matey - cant wait to get mine

[FD3SNuttah]

nice little write up, using some long words there too mate very impressive lol! so what do you need next boost controller? or have you got a Power FC?

So can i join in on the old terminal 100 mph 1/4 mile challenge??

**Quick update on mine** i have been phoning the guy doing my car every two days since hes had it (so he knows that its best to fix it and give me it back) hes saying it will be done within a couple of weeks, hes only got started making up the panels for it so far) slacker!!! got a bit of birthday money so instead of using it to clear some student debt decided to spend it wisely on the RX.

[Brett]

Am going to make a manual boost controller, should be fairly easy to do, then all I need is water injection and an additional injector (maybe) + the intercooler spray.  Then Grinders arse will be mine. (not in that way either!)
I\'m sure we can welcome more 2nd genners into the challenge. If thats the case I may have to write up a set of rules to go with it, just so that its fair for everybody.

[FD3SNuttah]

your stock boost gauge doesnt work now does it brett?

[Brett]

It does, just not very well I have an aftermakrket one I will get around to installing one day.

[clive]

Hi Brett,

Thanks for taking the time to put this together like you have, looks real good :cool

[Brett]

No worries Clive, Grinder and myself came up with the idea of a 2nd gen modifications thread awhile back.  The idea being that you create a thread like this when you do a mod or repair, then link it in the Sticky thread at the top.  
 Perhaps this idea should be fielded to the other Rx/rotary sections?
:wave

[Thud]

Brett - nice write up. What did you use to plug the AFM hole? I used the cork from a vinger bottle (?) but there may still be a slight leak as the idle is not as good as it should be when cold.

Stu

[Brett]

I found an old stopper from a radiator (god knows what from) that had a nice thread and an O ring at the top, it was just on the + side so I screwed it in and the o ring has ensured a nice air tight seal