Hello, I might be a total idiot for thinking this, but I found a Mazdaspeed 3 Turbo/manifold/intercooler on craigslist near me for $200. I couldn't help wondering how hard this would be to use on my 2005 Focus ST. As I understand it the 2.3L Duratec was originally a Mazda design anyway, could these parts work/fit? Has this been done before? Thanks
garagebandbrad
Yea the manifold & turbo will bolt on. ID believe the (hat) style intercooler would work as the hoods are different. Have you checked out Tri-point engineering?
Wow, that'll be nice. I'm surprised I can't find any cases of people having put a k04 mazdaspeed3 turbo setup on a focus if at least those two pieces are easy to install... all that's left is to install that intercooler up top and find a hood that fits (plus of course a new ecu and all the custom piping and sensors and tuning and oil / water connections etc...). I looked up tri-point, their website is down, but I found a pretty cool article on their mazdaspeed3 build. Looks nice.
Tri point is the company that did the r&d for Mazda for their Speed3. Tri point wanted to do a bigger turbo, but Mazda put the cabosh on it.
Unfortunately those fswerks kits (and most turbos...) cost around 3-4k. That's a lot to spend on a focus I spent 3k on... 200 is a great deal. But it's interesting to know those die out... It'd be a bummer to go through all the fab and install and it burns oil!!! I'm feeling I'll pass on this project. I did some more research through the forum and from what I found the mazda 3 manifold fits but not the mazdaspeed 3, different flange and bolts or something.
I have owned a Mazdaspeed 3, currently own Mazdaspeed 6, and have installed an MS3 turbo setup on a 2.3 focus (back in 2010). I doubt that I have any pictures but will try to help you out.
First of all, not everything swaps directly over like you are hoping. Main reason being the MS3 uses a top mount intercooler (TMIC) that would never work with the standard MZR/Duratec engine.
-Mounting- The MS3's intake manifold has 2 built in mounting points for the intercooler, which your Focus does not.
-Throttle body placement- Your focus throttle body is mounted up high, unlike the MS3. The factory intercooler's cold pipe would never line up. Not even close.
-Your Hood (should be the most obvious reason)- With the TMIC sitting on top of the engine you would not be able to close the hood, even if it could, the TMIC would have zero airflow, completely defeating it's purpose.
The solution to this- Use a universal/custom intercooler kit (2.25" is best). I used a CX racing universal kit on the Focus. But that itself leads to one issue:
-Turbo compressor housing- The K04 (MS3 OEM turbo) compressor housing will need to be clocked down (180 degrees vs the factory position. But is has a built in mount for the wastegate that would no longer line up as seen here:
http://gonzaloherrero.com/bnr/images/stories/MS367pic3.jpg
and here 20121102_204214.jpg Photo by miander1 | Photobucket
The solution- use a bracket to mount the wastegate 180 out. Like this:
JBR Turbo Clocking Kit for Mazdaspeed 3 / 6 #K04-CLK-KIT - Revolution Performance Motorsports!
With this you will be able to route your IC piping under the engine to a front mount intercooler (FMIC).
Other things to consider:
-A Focus with PZEV will not accept the MZR DISI factory manifold due to it's air injection system. This would cause an excessive exhaust leak at the manifold.
-The K04 will smoke, all do especially without cats. You can buy or make a better oil restrictor bolt that can reduce the chance of smoke. (search bnoon bolt how to, I believe Kinagawa sells them on ebay too).
-Your MAF housing isn't big enough. Will need to step it up to at least 2.75". I used a MAF housing from an '04-'06 Nissan Sentra SE-R, the 03 Focus MAF bolted into it but an '05's might be different.
-Downpipe/exhaust- A factory MS3 downpipe (w/cat) should physically fit, but would have to adapt to your exhaust. Most aftermarket downpipes will not have enough clearance between the alternator heat shield and will not fit, but CNT's downpipe seems to provide more clearance (might work).
-The K04 will need a coolant and oil supply. I would advise buying universal banjo fittings for the coolant and oil feed line. You could add a brass t-fitting to the oil pressure fitting for your oil source or buy a filter sandwich plate. Weld a -10an fitting to the oil pan for the return and make a custom line.
-Tuning- I used an SCT programmer and had it dyno tuned.
My recommendation:
DO NOT GO THIS ROUTE! Yes you can go this route, but In the end it will take more time to get everything to work and about the same price as a bolt on kit. (I've seen some of used kits from FSwerks and other major companies posted for around $2k)
-The K04 isn't the most reliable turbo, and it will smoke at red lights or after a pull (embarrassing).
-I'd much rather have an external wastegate than internal wastegate.
-If you do want to use the MS3 manifold, get a different turbo that will bolt up to it. Find a used ATP turbo(gt2871 would be perfect) with the K04 flange and internal wastegate. They pop up on eBay quite often.
First of all, not everything swaps directly over like you are hoping. Main reason being the MS3 uses a top mount intercooler (TMIC) that would never work with the standard MZR/Duratec engine.
-Mounting- The MS3's intake manifold has 2 built in mounting points for the intercooler, which your Focus does not.
-Throttle body placement- Your focus throttle body is mounted up high, unlike the MS3. The factory intercooler's cold pipe would never line up. Not even close.
-Your Hood (should be the most obvious reason)- With the TMIC sitting on top of the engine you would not be able to close the hood, even if it could, the TMIC would have zero airflow, completely defeating it's purpose.
The solution to this- Use a universal/custom intercooler kit (2.25" is best). I used a CX racing universal kit on the Focus. But that itself leads to one issue:
-Turbo compressor housing- The K04 (MS3 OEM turbo) compressor housing will need to be clocked down (180 degrees vs the factory position. But is has a built in mount for the wastegate that would no longer line up as seen here:
http://gonzaloherrero.com/bnr/images/stories/MS367pic3.jpg
and here 20121102_204214.jpg Photo by miander1 | Photobucket
The solution- use a bracket to mount the wastegate 180 out. Like this:
JBR Turbo Clocking Kit for Mazdaspeed 3 / 6 #K04-CLK-KIT - Revolution Performance Motorsports!
With this you will be able to route your IC piping under the engine to a front mount intercooler (FMIC).
Other things to consider:
-A Focus with PZEV will not accept the MZR DISI factory manifold due to it's air injection system. This would cause an excessive exhaust leak at the manifold.
-The K04 will smoke, all do especially without cats. You can buy or make a better oil restrictor bolt that can reduce the chance of smoke. (search bnoon bolt how to, I believe Kinagawa sells them on ebay too).
-Your MAF housing isn't big enough. Will need to step it up to at least 2.75". I used a MAF housing from an '04-'06 Nissan Sentra SE-R, the 03 Focus MAF bolted into it but an '05's might be different.
-Downpipe/exhaust- A factory MS3 downpipe (w/cat) should physically fit, but would have to adapt to your exhaust. Most aftermarket downpipes will not have enough clearance between the alternator heat shield and will not fit, but CNT's downpipe seems to provide more clearance (might work).
-The K04 will need a coolant and oil supply. I would advise buying universal banjo fittings for the coolant and oil feed line. You could add a brass t-fitting to the oil pressure fitting for your oil source or buy a filter sandwich plate. Weld a -10an fitting to the oil pan for the return and make a custom line.
-Tuning- I used an SCT programmer and had it dyno tuned.
My recommendation:
DO NOT GO THIS ROUTE! Yes you can go this route, but In the end it will take more time to get everything to work and about the same price as a bolt on kit. (I've seen some of used kits from FSwerks and other major companies posted for around $2k)
-The K04 isn't the most reliable turbo, and it will smoke at red lights or after a pull (embarrassing).
-I'd much rather have an external wastegate than internal wastegate.
-If you do want to use the MS3 manifold, get a different turbo that will bolt up to it. Find a used ATP turbo(gt2871 would be perfect) with the K04 flange and internal wastegate. They pop up on eBay quite often.
Great info^^^^^^^ I wouldn't use the K04 either. The op has a '05 so no pzev so no issue there. Like said, I'd go w/ the gt2871 rs.
awesome thread! i am beginning to consider throwing together a turbo kit for my focus. This was very helpful
well it's 5k for the fswerks kit.. i was thinking to throw something together for 1.5k but it's seeming like a lot of hassle and time and i'm currently pretty happy with my NA setup hahaha. kinda making me realize I'm good without boost for now.
exactly what I'm doing. I'm really pleased with the D23. been doing some power building just starting to move on to suspension.
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