Mazda MX5 Mk2/Mk2.5 1.6 Turbo Kit with Sports Cat Intercooler Downpipe Fittings

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

Please note we have deliberately omitted the turbo from the kit to give you full flexibility in choosing the turbo that best suits your setup.

It is designed to run with a Garrett GT2860RS or GT2871R, or any hybrid using the same dimensions. This allows you to use a budget eBay version, a second-hand unit from a Nissan 200SX (with compressor side adapters), a Garrett GT2860/GT2871, or even the popular Disco Potato.

Recommended Compatible Turbos:
– GT2860RS journal bearing, spool at approx. 2750 RPM – Ideal power 230 to 370 BHP
– GT2860RS ball bearing, spool at approx. 2400 RPM – Ideal power 230 to 370 BHP
– GT2554R journal bearing, spool at approx. 2000 RPM – Ideal power 170 to 270 BHP (note: will require an adapter piece for the turbo-intercooler pipe)
– GT2554R ball bearing, spool at approx. 1650 RPM – Ideal power 170 to 270 BHP (note: will require an adapter piece for the turbo-intercooler pipe)

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), oil return (with sump fitting), and water feeds.

A 200-cell sports catalytic converter is included.

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

On the hot side, the manifold is a 3mm-thick log type, flowing 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 differential.

A BOV flange is welded into the intercooler pipework to accept 50mm Tial BOVs—compatible with genuine Tial or aftermarket options.

This kit was not designed to use the Mazda MAF meter, so standalone management or custom adaptations will be required. There is a 3/8 NPT boss welded into the intercooler pipework ready for a GM-style open element IAT sensor. Budget-friendly options include Megasquirt or ME management, or you may opt for AEM or Link upgrades.

Fuel injectors: the standard injectors do not flow enough for a turbo setup. RX8 Yellow or Blue injectors are recommended on a budget, or high-performance options such as Deatschwerks or Injector Dynamics.

The OEM clutch is not suitable for turbo power. A Competition Clutch Stage 4 or equivalent is recommended.

List of All 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 clamps
1 x 2.5″ Stainless downpipe
1 x 2.5″ Stainless centre pipe with sports cat
1 x 2.5″ Stainless rear diff passing pipe
1 x 2.5″ Gasket bolts
1 x 1/8 NPT T-Piece
1 x 1/8 NPT 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° at the other
1 x AN-10 sump adapter, uses 1/2 NPT 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° turbo to intercooler pipe silicone elbow
1 x 2″ to 2.5″ 90° expanding silicone elbow (intercooler pipe to intercooler)
1 x 2.5″ 90° silicone elbow (intercooler to intercooler pipe)
1 x 2.5″ 90° 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

Parts Required but Not Included:
1 x Turbo – ideally a GT2860RS
1 x BOV – 50mm Tial-type required
1 x ECU – Megasquirt or similar with IAT sensor required
4 x Injectors – Mazda RX8 Yellow or Blue recommended
1 x Clutch – Competition Clutch Stage 4 or similar recommended
1 x Air filter – measure size of chosen turbo intake