Mazda MX5 Mk2 or Mk2.5 1.6 Turbo Kit w. GT2860RS

This is a foundation kit containing all the parts you will need to fit a turbo to a Mazda MX5 Mk2 1.6.

What’s inside?

All the fittings are supplied to fit any of these turbos including the oil feed (plus adapter to the oil pressure switch) and return (with sump fitting) and the water feeds.

The intercooler supplied is rated to 400 BHP and comes with the brackets, silicone hoses and couplers with T-bolt clamps and aluminium pipework. The pipework has a flange for the 50mm Tial-type blow-off valves and a 3/8 NPT boss for an IAT sensor.

On the hot side, the manifold supplied is a 3mm-thick log type, this will flow enough for over 300 BHP. The downpipe has an M18 boss welded in for a wideband lambda sensor and connects to the standard exhaust just after the diff. There is no cat in this pipe so it will not pass a UK MOT test.

A sports cat pipe is available to comply with UK emissions regulations and can be run permanently as long as the car is mapped well and you are not using any feature which causes excessive flames, for example anti-lag.

For the BOV, there is a flange already welded into the intercooler pipework which accepts the 50mm Tial BOV, here you can choose to go for genuine Tial or have a look on eBay to see what is available.

This was never designed to use the Mazda MAF meter so you will need to run some form of standalone management or make your own adaptions. There is a 3/8NPT boss welded into the intercooler pipework ready to take the popular GM open element IAT sensor. Megasquirt or the ME management is a good budget option or perhaps spend the extra on an AEM or Link upgrade.

The standard injectors do no flow enough so again it is recommended to go for the RX8 yellow or blue ones if on a budget or choose something like Deatschwerks or Injector Dynamics if the budget will stretch.

Finally, the OEM clutch won’t withstand the power once a turbo has been fitted so a Competition Clutch stage 4 or similar is recommended.

Here is a list of all the parts included:

1 x Turbo manifold
1 x Head to manifold gasket
1 x Manifold to turbo gasket
4 x Manifold to turbo studs and nuts
1 x Turbo to elbow gasket
5 x Turbo to downpipe studs and nuts
2 x 2.5″ V-band clamp
1 x 2.5″ Stainless downpipe
1 x 2.5″ Stainless centre pipe
1 x 2.5″ Stainless rear diff passing pipe
1 x 2.5″ Gasket bolts
1 x 1/8NPT T-Piece
1 x 1/8NPT to AN-3 adapter
1 x Turbo oil feed line
1 x AN-3 to banjo fitting
1 x Banjo bolt with washers
1 x T28 to AN-10 oil drain fitting
1 x AN-10 oil return braided hose, 40cm long, straight fitting at one end and 30 degree at the other
1 x AN-10 sump adapter, uses 1/2NPT thread to go into the sump
1 x AN-6 water feed braided hose, 50cm long, open at one end, AN-6 straight fitting at the other
1 x AN-6 water feed braided hose, 40cm long, open at one end, AN-6 straight fitting at the other
2 x AN-6 to M14 banjo fittings with bolts and washers
2 x AN-6 hose finishing clamps
2 x 19mm to 10mm T-pieces
4 x Jubilee clamps 25mm
1 x 2″ 90 degree turbo to intercooler pipe silicone elbow
1 x 2″ to 2.5″ 90 degree expanding silicone elbow from intercooler pipe to intercooler
1 x 2.5″ 90 degree silicone elbow from intercooler to intercooler pipe
1 x 2.5″ 90 degree intercooler pipe to throttle body silicone elbow
8 x T-Bolt clamps
1 x Intercooler
2 x Intercooler brackets
2 x Intercooler aluminium pipes
1 x Set of intercooler bolts
1 x Turbo – GT2860RS
1 x BOV – 50mm Tial-type
1 x RAMAir Air Filter

The below parts are also required but not included in this kit:

1 x ECU – Will need a Megasquirt or similar with IAT sensor
4 x Injectors – Mazda RX8 Yellow or Blue work well in this car
1 x Clutch – Competition Clutch stage 4 or similar is recommended