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MAZDA 3 MPS INTAKE

INSTALLATION

Tools required

7mm hose clamp driver

10mm and 12mm socket and suitable ratchet

Stanley knife

Phillips head screwdriver

Needle nosed pliers

3mm allen key

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1. Start by opening the bonnet and loosening the two jubilee clips holding the filter outlethose, and unclip the MAF sensor plug by squeezing the rear of the plug and pulling it off.

2. Pull up the clips that retain the top of the filter housing and remove it from the car

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3. Remove the rubber outlet hose still left in the car, by first removing the breather hoseattachement (push fit), then pull the base of the filter housing sharply upwards to release it

from the two rubber grommets in the chassis, and remove it from the car.

4. Remove the battery from the car by loosening and removing the earth and positiveterminals with a 10mm socket, then remove the two 10mm buts on the retaining bracket

that holds the battery into the cover.

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5. Remove the single 10mm bolt under the battery that holds the battery cover to the chassis,and the two 10mm nuts that holds the ECU bracket to the chassis on the front edge of the

battery cover. Pull the ECU bracket up and off the two studs.

6. Now pull the battery cover upwards and roll it forwards at the same time. The front face ofthe battery cover unclips so that the negative battery terminal wiring can be pulled free.

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7. Remove the phillips head screws holding the ECU onto the battery cover, then unclip thefront of the battery cover (this part stays in the car) and remove the rest of the battery cover

from the car. The ECU can be positioned temporarily in the space left by the battery.

8. Remove the single 10mm nut holding the turbo inlet pipe to the engine, remove the clipholding the wiring using needle nosed pliers,and remove the scissor clip holding the dump

valve return to the inlet pipe.

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9. Near where the pipe enters the turbo, remove the clip holding the small vacuum tube to thepipe, pull the pipe off, and undo the jubilee clip securing the inlet pipe to the turbo. The inlet

pipe can now be removed from the engine bay.

10.Remove the other end of the breather pipe removed in step 3 from the back of the camcover, the two green plastic prongs need to be pushed in in order to remove the pipe.

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11.From the inlet pipe you removed, take off the rubber mount and rubber hose insert asshown and fit them to the provided Forge pipework. Fit one of the supplied jubilee clips

around the rubber hose insert (loosely) ready for installation.

12.Remove the front right bolt 12mm on the gearbox shifter mechanism this can be tight sobe careful not to round off the bolt head.

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13.Lower the Forge pipework into the engine bay taking care. Tuck the turbo end under thewiring as you do so and push the rubber grommet you fitted in step 11 over the threaded

stud that held the stock pipe in place. This should line up the pipe with the turbo inlet which

can now be pushed on too.

14.Bolt the remaining bracket loosely to the top of the gearbox using the bolt removed in step12, then tighten the jubilee clip on to the turbo housing, the 10mm nut on the stud and the

bolt on the gearbox in that order.

Line this up first

Then push this onto turbo inlet

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15.Cut down the dump valve recirculating pipe with a sharp stanley knife in order for it toconnect to the Forge pipework. If you also have the Forge Front Mounted intercooler, then

the slight bend at the end of the recirc pipe is a perfect fit.

16.We provide a small attachment on the pipe in order to use a cable tie to secure the upperwater pipes to the intake if necessary.

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17.Fit the short breather hose supplied to the Forge pipework and the cam cover, using the22mm jubilee clips provided.

18.Remove the MAF sensor from the stock airbox and secure the MAF to the Forge pipeworkusing the two M4 screws provided, and plug the MAF sensor back in to the loom.

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19.Jack the car up and remove the left front road wheel, and the screws securing the arch liner.Mount the Forge splash guard over the vents in the arch liner, and use a 7mm drill bit to drill

four holes through the liner, then use the provided M6 bolts and penny washers to secure

the splash guard to the liner.

20.Fit the aluminium trumpt into the airfilter, and the remaining 90 degree silicon bend to therear of the trumpet with the provided jubilee clip. Use the last jubilee clip to secure the

silicon bend to the pipwork fitted earlier. Orientate the clip so that it can be done up from

within the arch as shown.

Installation is complete ! Refit the arch liner and wheel, and lower the car to the ground toenjoy your new found perfromance.