MS CAI and Forge BOV HowTo

[jb606]

MAZDASPEED CAI and Forge Blow Off/Bypass Valve (BOV / BPV ) Installation (Photos Coming Soon)


Why: Replace leaking factory BOV and free up some HP


Target: Anyone with basic hand tools wanting to upgrade there stock MS6


Car: Stock 2006 MAZDASPEED 6 GT



WARNING:

1. This how to is designed to give a general understanding of the installation process. If said parts are installed incorrectly MAJOR DAMAGE to your car is POSSIBLE.

2. The parts installed in this howto can have a negative affect on your warranty.

3. INSTALL AT YOUR OWN RISK!!!


Safety:

1. When using anything to lift a vehicle off of ground please chalk the wheels that will remain on the ground.

2. Use any necessary personal safety equipment ie. Safety glasses, gloves, steel toe boots ( yes they have saved my feet many times )


Disclaimer: Author is not responsible for any damages or injurys.


PLEASE USE COMMON SENSE and TAKE YOUR TIME!!


Tools:

1. Ratchet with 10,11,12, and 14 mm sockets. 2 in extension.

2. Phillips screwdriver.

3. Flat screwdriver.

4. 3.5 mm alen wrench.

5. Two ton jack and two jack stands.

6. Tire Iron ( the key if you have locking lugs )

7. Channel lock pliers


Time: 2 - 3 hours


Steps:


CAI Installation

1. Open the hood and locate your battery



2. Remove your negitive(-) battery terminal. ( 10mm socket )



3. Remove the two (2) bolts the hold the TMIC cover down ( 10mm socket )



4. Disconnect the MAF sensor.



5. Loosen the hose clamp closest to the MAF.



6. Un-clip the four (4) clips the hold the air box closed



7. Lift the air box lid and pull the lid off of the intake hose ( this may require some twisting and pulling ).



8. Lift up and remove the lower half of the air box.



9. Remove the two bolts of the brass colored bracket that held the air box in place ( 11 or 12 mm )



10. Push down slightly on the PCV hose then squeeze the bottom blue piece then lift the PCV hose off.



11. Transfer the blue connector to the CAI.



12. Jack the car up and remove the driver's side ( left side ) wheel.



13. Remove the three (3) plastic screws and their fasteners ( circled in red )



14. Underneath the car remove the four (4) phillips screws. ( circled in red )



15. Remove the resonator ( lower air box )

There are three (3) 14mm nuts that hold this thing on to the frame rails and yes this can be a PITA

The two in the back use your extension ( sorry no pics my camera couldn't get a clear shot )



16. Install the coupler and the elbow with the PCV nipple to the turbo inlet.



17. Connect the PCV hose ( you may need to rotate the PCV connector as well as the the elbow to get the correct alignment )



18. Screw down the rubber mount to the forward hole where the air box mounting bracket that was removed.



19. Slide the small coupler on the elbow and install the main CAI pipe.



20. Slide the CAI on to the rubber mount and install the washer and the nut to hold down the CAI ( 14mm ).



21. Transfer the MAF from the stock air box lid to the CAI ( phillps for the stock box and 3.5 alen for the CAI )



22. Install the air filter on the end of the CAI and tighten the clamp.



23. Tighten all the clamps ( Turbo inlet, elbow, main pipe )




24. Reinstall the fender well and put the tire back on.


BOV Installation.


NOTE: I am running a stock turbo so I used the 15lb ( yellow ) spring.



1. Remove the vacuum from the top of the stock BOV.



2. Remove the two (2) 10mm bolts. ( Be careful this is all aluminum )



3. Remove the recirculation hose from the stock BOV

4. Install the O-Ring that came with the Forge BOV.

5. Install the Forge BOV in reverse order.



Connect your negitive (-) battery terminal ( 10mm )


Double check all of your connections


Re-program your windows by rolling the window down about half way

Then roll the window up and hold the button in the up position until two (2) clicks are heard do this for all four (4) windows


Start the car and go for a test drive.

[lynx]

Just I quick write up for how to install a MAZDASPEED CAI and a Forge BOV

HowTo
JB[/b]

Wow, thanks a ton. I'm receiving MSpeed CAI on Wednesday and going to install on Thursday or Friday. The pictures help out greatly. Going to save that webpage on my desktop and print it out.

[SpeedE]

That's a very nice write up, should probably mention to reset all 4 windows. I scared the hell outta my self when I installed my CAI.

[jb606]

Added window re-programing

[mk706]

good how to.

i'd mention there's no requirement for lifting the car or removing the wheel. it's pretty easy to get the resonator box out & filter on with the wheel turned all the way to the right. if you leave the wheel on you'll need a 90 degree offset driver or short phillips screw driver to get the plastic pins that hold the fender liner in place.

[digger10t]

It's also very easy to get the resonator box out by removing the driver's side fog light. This allows you to access the bolts directly with no extensions or other attachments.

Nice writeup!

[jb606]

The major issue I had with not removing the front tire was not getting to the bolts, it was getting the resonator out of the fender well.

[SpeedE]

I think it's perfect! Can't imagine how much of a PITA it would be w/o removing the wheel. Then again, I've never tried it the other way.....

[mk706]

the total job without lifting or removing the wheel is ~30 minutes.

this reminds me of the CAI write-ups 2 years ago, in that case just about every write-up said removing the bumper is a must. to each their own. i'd rather remove only what's necessary.

[jb606]

I wrote this for people who have never done anything with there MS6. That is why I said it would take 2-3 hours. It took me longer to do the write up then it did to do both the BOV and CAI install.

I have to stand fast on taking the front tire off it is just easier to take the wheel off then to try to contort yourself to get the resonator out. Been there done that.