Group Buy: 505 Intake Manifold Round 2

[bwalt]

And 6 hours later... installed. Car feels good, I like the smooth power band. Stock fuel rail was a pain, EGR an even bigger pain. I have to get proper fittings to attach the hose to the exhaust mani and to the EGR block on the intake mani. The one adaptor included wont work, at least not that I can see. Had to slightly enlarge one hole on the throttle body and re-located my MAF too while I was in there, got so nervous chopping my corksport intercooler pipe but everything fit after all.

 

[hdiddy27]

I got a corksport fmic too and I was wondering where to cut it. Did you have to cut it straight and use a 45 or could you cut it on the bend and use the straight coupler?

 

[Spiced MSP]

good question, I definitely want to know as well when the time comes to install mine as I also have a CS FMIC

 

[2.0t03speed]

And 6 hours later... installed. Car feels good, I like the smooth power band. Stock fuel rail was a pain, EGR an even bigger pain. I have to get proper fittings to attach the hose to the exhaust mani and to the EGR block on the intake mani. The one adaptor included wont work, at least not that I can see. Had to slightly enlarge one hole on the throttle body and re-located my MAF too while I was in there, got so nervous chopping my corksport intercooler pipe but everything fit after all.

are you trying to attach the stock egr line?

 

[jbrewer4639]

here's a low resolution pics of the 505 with some other stuff i've been hoarding.

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[hdiddy27]

if you put all of that on at the same time you car is going to feel completely different. And in a good way

 

[repthemazdas]

wow thats nice^^^^

 

[mazdaspeedp]

Hope mine gets here soon than my motor will be going in

 

[jbrewer4639]

Thanks guys I got to get all the gaskets, hardware, rods and pistons, and machining done and then the fun begins

 

[bwalt]

are you trying to attach the stock egr line?

Negative, trying to use the included line and fitting.

 

[505zoom]

Negative, trying to use the included line and fitting.

The included male flare->male NPT fitting works on the IM block, and the female flare on the other side of the flex hose hooks directly up to the exhaust manifold. Shouldn't be a reason it doesn't work... all of the hoses and fittings are the same and I just double checked with one that is still here.

 

[bwalt]

I got a corksport fmic too and I was wondering where to cut it. Did you have to cut it straight and use a 45 or could you cut it on the bend and use the straight coupler?

good question, I definitely want to know as well when the time comes to install mine as I also have a CS FMIC

I used a 2.5"-2.75" 45 degree coupler and a 2.75" to 2.25" straight coupler. Cut the elbow about 3 inches before the weld and trimmed the silicone a bit too. The location of my BPV made it tricky to squeeze in the MAF re-location, it just barely fit. If your not re-locating the MAF then just a 45* 2.5" to 2.25" coupler will work. Remember to take your time measuring and fitting everything into place and everything will be ok. Cut less rather than more, then you can cut again if needed.

Be careful too when threading the brass fittings into the manifold, its easy to strip aluminum. Mine had slight over-spray from the powder coaters on the first couple threads making it hard to get started. Ran a tap through to clean them up. There's no way the stock fuel rail will seal with the original black spacers, so I used the included washers instead. Also cut the rear tabs of the rail to clear the plenum. I'll try to think of more tips for you guys, if anyone has issues don't hesitate to ask, I'm happy to help.

Sorry for the cell phone pics..

One more, just for fun

 

[bwalt]

The included male flare->male NPT fitting works on the IM block, and the female flare on the other side of the flex hose hooks directly up to the exhaust manifold. Shouldn't be a reason it doesn't work... all of the hoses and fittings are the same and I just double checked with one that is still here.

The threaded portion on the exhaust manifold for the egr came right out, the fitting is seized. Cut and crimped the pipe for now to plug the hole. That part isn't anyones fault, it just happend and I'll deal with it.

The problem I'm having is the side of the fitting being pointed at here threads into the egr hose. That same side also threads into the EGR block.. the other side is too big, at least to me anyways. All I would need is a different adaptor.

 

[505zoom]

The threaded portion on the exhaust manifold for the egr came right out, the fitting is seized. Cut and crimped the pipe for now to plug the hole. That part isn't anyones fault, it just happend and I'll deal with it.

Oh that's a bummer.

The problem I'm having is the side of the fitting being pointed at here threads into the egr hose. That same side also threads into the EGR block.. the other side is too big, at least to me anyways. All I would need is a different adaptor.

Hmmm... very strange... the block is supposed to be a 1/2" NPT thread, not a 1/2" flare thread. I'll have to look into this more and see what's going on with that.

 

[hdiddy27]

So after 10 hours install I find out that the egr hose that connects to the exhaust is too small. I cut the end of the old hose off and it screwed right on. The new one won't even start threading. Any help would be nice.

 

[hdiddy27]

So I measured the inner diameter of both. The original is egr end is 13/16 and the new is 3/4

 

[bwalt]

So after 10 hours install I find out that the egr hose that connects to the exhaust is too small. I cut the end of the old hose off and it screwed right on. The new one won't even start threading. Any help would be nice.

I'm in the same boat as you man, waiting on 505 to see what's happend..

 

[mazdaspeedp]

Damn so egr is ****** guess ill be looking for a custom part soon than

 

[hdiddy27]

Besides getting this fixed which is number one priority. Can I just block off the exhaust like Walt did and leave the hose unattached without any problems? I really need my car.

 

[2.0t03speed]

yep alot of people just cap off the exhaust side of the egr and leave the intake side open.