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bloodyspirit058
03-05-2011, 02:46 AM
well i figured its time to start a worklog thread, if things work out should be able to do some interesting stuff in a bit.

alrighty, to start this off, my 96 was involved in a "i hit the brakes and it just slid into the car that pulled out in front of me" wreck (no, i was not driving it...and no, neither the 95 or 96 dx's i have, have ABS)

so i drove it around for a bit, than found the 95 on craigs list, runs but doesn't move... manual, no AC manual windows.... besides the non moving part sounds like my kinda car, so i go look at it, way better condidtion than my old one, couple dings behind the rear right door, thats really about it.

so thinking its the transmission i start tearing things out and the left axle just falls out with the tranny side still in the car... ok, well i lucked out, its just an axle... so i get a reman'd axle and throw it in. tons of clanging later i realize i was correct with my first hypothesis and it is the tranny, i'm guessing spiders or final drive gear as the tires are not connected really in any way.


so i picked up a tranny today, sorry no pics for right this sec, i get to excited to start working i forget to take pics, it had a slave cylinder and sensors on it, i guess they are from a 97 and i can already tell some of them look a little different but switching back to the originals should be no problem, pics in the morning :)

(the car isn't as dirty as it looks, it was just extremely dark and the camera didn't like it)

irishkev90
03-05-2011, 10:44 AM
Yay, more second gen work! Hope everything goes well for you.

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bloodyspirit058
03-05-2011, 07:50 PM
so apparently the whole two objects can not share the same place applys to shift linkage and exhaust componets as well... so while i'm taking a brake from beating everything with a hammer some more pics :)

oh ya, and the last picture reminded me, the left axle is still stuck in there... never had a problem getting them out, but a 3 ft prybar wont do it... i'm ready to hook it up to my truck and pull it :P

bloodyspirit058
03-06-2011, 12:04 AM
so just a tiny bit of updated news, got the tranny out with the left axle still in it (don't ask how) than a short pry bar with constant pressure and a broken screw driver through the dif i was able to get it out. It's slow going but should have it working by next weekend

bloodyspirit058
03-09-2011, 10:07 PM
just a small update, tranny and axles back in, i got some new ball joints, not only were they stiff as hell, but both had random (not even close to oem) bolts half holding them on (they were tight, but the bolt and nut didn't really go together and it didn't seem all that safe) so i got the cheap red box ones through carquest with mounting hardware.

i have a question though, anyone know what the sensor on the front of the transmission is? has a large white connector, i know my 96 has it cause i've had to zip tie it up outa the way, but the 95 had it ripped all the way off and i see the wires hangin down by the fender and the new tranny came with the sensor and connector... so i was wondering what it is before i either ignore it or wire it back up wrong

Ace
03-09-2011, 10:30 PM
Reverse sensor. was your car originally an automatic?

bloodyspirit058
03-09-2011, 10:58 PM
Reverse sensor. was your car originally an automatic?

no, i know on my 96 that the plastic thing broke and it hung low, the sensor in the original tranny had the wires missing a long time ago (no visable wires at the sensor but it was covered in dirt) and i see the green wires by the air box inside the left fender, i'm guessing the connector just came unmounted and snagged on something.

EDIT: well i take that back, i just got the car and i'm assuming it was orginally a manual, but it also has like 192k on it, so i'm not sure what has and hasn't been done on it.

irishkev90
03-10-2011, 09:35 AM
What's the 4th number in the VIN after the 5 letters? Basically the 9th digit in the VIN. I think if it's a 5 then the car was built as an automatic, a 2 means it was built as a manual.

Someone correct me if I'm wrong.

bloodyspirit058
03-10-2011, 11:02 AM
it is a 4...

irishkev90
03-10-2011, 11:53 AM
Hmm, looks like I'm wrong. This is where I got my information about the VIN decoding.
http://allmazda.net/parts/323/AEBA06/Y9/VVVV/EBA06V1/

bloodyspirit058
03-11-2011, 11:04 PM
well i got some new parts and got everything put back together, problem is i started the car and with the clutch in something is making a noise like something in a fan, but since its a electric fan and its freezing outside, i don't think it was on.

but all except for that little setback its together and after i find the noise ill make sure the tranny is actually working

pics for now:

irishkev90
03-12-2011, 10:42 AM
Nice! 2.5 gen garnish. Now you need the JDM tail lights to make the rear look right.

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bloodyspirit058
03-13-2011, 04:20 PM
well it made a couple funny noises but they went away, the car drives fine, little wobbly on the front end, but since the right side of the front sway bar is not hooked up it doesn't surprise me.

engine idles a little crappy, but it hasn't really ran in over 2 months and the previous owners said they didn't know much about cars. i'm gunna need a coolant reservoir cap (was some random radiator cap on there before :S) actually i'm gunna need some other stuff, should start making a list

so as long as things stay on track, 1.8L should be purchased some time in 2-3 weeks



ok, list as of right now:

coolant reservoir cap
sway arm mount bushing (correct term?)
brakes (dunno how the back looks so far, would like 4 disk swap)
passenger door mirror
shift boot
jdm rear corners


ne one think of anything else? i've been doing the whole "its almost finals week" stuff for school so im sure i've forgotten to look at something

will probably have a separate list for stuff that will come with new engine: plugs wires, rad hoses ect

irishkev90
03-13-2011, 07:55 PM
Do you mean the sway bar end link?

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bloodyspirit058
03-13-2011, 09:52 PM
well here is a pic, i'm sure you can spot the broken part :P

Mazda_Powered
03-13-2011, 11:07 PM
stupid design for an endlink lol, my 626 is like that too, slightest play and they sound like your front end will fall apart when driving

irishkev90
03-14-2011, 12:14 AM
What broken part? ;)

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bloodyspirit058
03-20-2011, 02:25 AM
just some new pics from today

bloodyspirit058
03-22-2011, 01:24 AM
so i've been thinking of ecu's for when i do the engine swap, and since i plan on turbo at some point i've been thinking on just going with a megasquirt system and go from there. after reading through SOME of the technical stuff on the site i'm thinking this might be a good option.

irishkev90
03-22-2011, 06:42 AM
Should definitely go with Megasquirt if you're looking at some high boost numbers.

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bloodyspirit058
04-14-2011, 12:33 PM
well i picked this up yesterday, hopefully i'm well on my way :)

bloodyspirit058
04-15-2011, 01:00 PM
figured id post up some pics, its going to be a little slow going, but i should have the ecu ordered today or 2morrow.

my plan so far is to just have a stock 1.8L get it running on the megasquirt computer, play with it till i have enough money to rebuild engine and add turbo... than redo it all while keeping the ecu and using the previous experience to tune it...again...

bloodyspirit058
04-20-2011, 07:19 PM
alrighty, just some updated news:

took valve cover off, sludge everwhere, was kinda mad/sad, but it started cleaning up nicely, i've been finishing the job with diesel with the oil pan off.
speaking of oil pan, i read that auto's have a different one, i still need to locate the difference as i bought an auto motor but its being mated to an f-series manual atm... (g-series later when money comes...)

fuel rail was kinked, just bought a salvaged one from flying miata as they had plenty and for way cheaper (even with shipping) than my local junkyards
also ordered: megasquirt 3 ecu with msx3 chip, cept for the delay in payment (some credit card issue with id and w/e) it should be on its way soon.

some other good news: the injector harness plug is exactly the same on a 95 pro and 96 kia, so i probably won't have to rewire that (might have to move pins, still need to check on that part) but otherwise it looks like everything is going to pretty much be a direct swap.

things i'm still not sure about:
egr 6 pin connector using (iirc) 4 wires to the 1.8 egr, 1.5L from what i saw uses a 3 wire connection :(
VICS this should only be a short term problem as the mega squirt ecu has optional outputs and i'm sure i can wire the vics system to one of the outputs for WOT

other than that things should be moving pretty good :D

bloodyspirit058
04-27-2011, 08:49 PM
so mega squirt is being built, kinda hit a road block as its not doing something its supposed to... :S

anyway, as i was taking a break, i found this video on youtube, and noticed a sweet car in it... at the time its only 1-2 years old and man those headlights are the clearest i've ever seen :P

http://www.youtube.com/user/copscarsandcrashes?feature=iv&annotation_id=annotation_849447#p/c/E1EF3C4F6FAF4785/21/VrppWREpFFs

irishkev90
04-28-2011, 06:38 AM
Hahaha, nice find :)

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wgneyz
04-28-2011, 07:04 AM
nice build man

bloodyspirit058
05-02-2011, 01:45 AM
so just to update a bit, megasquirt is coming along nicely (at least i think so) managed to pull up some wiring diagrams for my car so i can figure out what type of idle air control it uses, it does in fact not use gm's 4 wire w/e bs, its just a 2 wire valve, so that part of the board should be done within about 10 minutes... next part i'm working on is spark control, which i think i'm just wiring for a single high output spark (just using standard "coil in distributer" equipment that came with the motor [actually using z5 distributer, napa part #'s match and car-part.com says they are the same thing also, and the bp didn't come with one])

other than that nothing else really new, i miss the car though, i lent it to my parents so i could figure out what was wrong with my dads pickup, its been a week w/o it and i want it back now... well one more week to go and ill be able to start installing the computer and see how bad i can break things.

oh! new parts (no pics cause its not really that huge of a deal) got a 2 wire plug for the reverse sensor on the tranny (old tranny didn't have the wires from the sensor, and car doesn't have the plug in, new tranny came with complete sensor/wire/plug) so when i get the car back i can wire that in, plug is off some random year escort (not the egt body style, newer than that) connector on an 02 zx2 or escort or whatever they're called at least looks the same (had my friends car in the air and noticed) so i snagged one at the jy. the other new (well new to me) part is the button for the folding rear seats, one seat was missing one so i grabbed 2 at the jy also.

EDIT: also no laughing at my soldering, even though they STRONGLY recommend not letting megasquirt be your first time, i did it anyway, buddy of mine looked at it and said he couldn't believe it was my first board soldering (he took an electronics class [maybe more than one?]at the local university as part of his field of study)

irishkev90
05-04-2011, 09:01 AM
Sounds like you're coming along nicely. If you want some JDM tail lights to go with the new garnish check out 95pro's for sale thread: http://www.clubprotege.com/forum/showthread.php?t=52009

bloodyspirit058
05-04-2011, 02:42 PM
well i was coming along nicely, and ty for the post on the tails, i do need some, ill have to talk to the wifey...

so the bad -
i got the tray and oil pan on the motor finally after problems finding the rubber parts that go on the main seal housings ( parts guy typed in a 98 kia, and that is different from the bp 96...) and i put all the pan bolts in and BAM! the 4 that go in the oil pump are all stripped out cause the previous person over torqued them. well thats cool, i guess, cept a new one from napa is like a 130 bucks and i wasn't supposed to need anymore parts.

the good -
finished my computer, well i'm not exactly sure if i have the sensor settings correct, but it is setup for single high current output (wiring diagram says the computer is connected directly to the coil (no igniter)) and is setup for a 2 wire IAC (which if you read the directions, they are really kinda pushing wiring it for a 4 wire gm style stepper, so it was kinda annoying to figure out exactly how to do it)

so i get the car back at the end of this week, i might go ahead with the computer swap and see if i can at least get it ready for the bp than just drop the bp in and start with that... still not sure what i'm going to do yet, just figured that would keep things pushed forward instead of standing still waiting for the motor

bloodyspirit058
05-23-2011, 07:03 PM
just figured id update everyone...

so i finally got rid of the last of the 98 kia stuff, engine has new water and oil pump, new timing belt, its all timed and almost ready to go, just need the valve cover and oil pan back on it (didn't have that much time at school which is where the engine sits currently)

progress on swapping the ms ecu to the protege was delayed by the pilot bearing basically exploding in my dodge, so it got a new clutch (pilot bearing on last clutch job was installed backwards... good job who ever did that) somehow from the time i had the protege in the garage last till now, it filled up with crap, so i've been sorting and cleaning last couple days off and on, as soon as i get that done the car is going under the wrench... well mostly a screw driver and some wire snips

I've decided to keep the stock ecu onboard to do all the little things with egr and evap, so i'm researching that, one thing i need to go out and do is find out if the stock ecu using 2 different bias resistors or just 1 (i also need to unsolder the bias resisters on the ms ecu :( ) should be a fun mess :D

bloodyspirit058
06-09-2011, 12:27 PM
not a lot of progress happening, but a little -

got the bp home again, just need to put oil in it (will do after install) other than that, should be ready to go (might need a new vics pod...)

when i got the car the cel was either burnt out or missing, and since over half the dash/console is missing right now, i figured id address that. turns out it was removed (figures, but like i said i already knew it wasn't functioning when i bought it) to i took the ABS light (car didn't come with it) and installed it for the cel. it stays on now, go figure. codes p0120 (i think it was a p0...) and 510 iirc. IAT short or open... great, thats helpful, im planning on using that sensor for the ms ecu... so now i need to figure out where the wires are messed up, just doing an ohm test i got .6 on the power side and 1.2 on the ground side (this is all going from the sensor to the stock ecu) those measurements aren't bad, i also measure the sensor, seemed ok, threw it in the freezer, works fine...

EDIT: so after googling the codes it comes up as a tps problem, not iat... i'm guessing the autozone guy was incorrect with his info... now to test the tps circuit

bloodyspirit058
06-13-2011, 07:43 PM
so, MS is hooked up, i'm thinking on ditching the evap system, not sure yet, right now i'm just trying to get an engine to work with it, one thing i need to do is calibrate the temp sensors... anyone know the values they are supposed to be for this year?

bloodyspirit058
06-14-2011, 03:03 PM
alrighty, sensors are all go, just not getting crank signal, and maybe not a cam signal...

bloodyspirit058
06-25-2011, 02:57 AM
just a quick update, fixed the input signals (forgot 2 transisters on the main board) had some problems with the spark (fixed tonight thanks to MD323) and since i had spark i adjusted with a timing light, said good enough, hooked the injectors up and it fired right up

problem now: it idles at around 2200 and climbs (idle air full open? disconnected? dunno yet, but its late right now)

the other problem: its still the z5 :P

EDIT: just a further update: drove it up the street and back, little rough around the edges, but i'm not going to fine tune it, just wanted to prove it works so that way if something doesn't work on the bp, i know its the bp and not the ms... probably start the swap monday or so, been looking for a job, so that takes a lot of my time also

bloodyspirit058
06-28-2011, 11:59 AM
just a new update:
http://www.clubprotege.com/forum/attachment.php?attachmentid=49887&stc=1&d=1309276535

picture is a little blurry, it was taken with a droid around 8 with only 1 overhead light

other notes: i'm also waiting for a puller to get the metal bit outa the crankshaft so i can get this moving again

bloodyspirit058
06-29-2011, 08:08 PM
well i got the engine in, went really smooth. well smooth until i realized...

the half shaft doesn't work :( so now i need to find which half shaft i need and the axle to go with it :( currently using the f series, so im assuming a 96-98 es half shaft? good luck to me finding one of them. any way, on to the new pic

3ni_tricksta
07-02-2011, 03:18 AM
what a bummer on the shaft.

bloodyspirit058
07-05-2011, 06:44 PM
what a bummer on the shaft.

ya, i've been trying to find a 2nd gen full length shaft to use as a temperary fix till i get funds for the g-series, but not much luck finding one in the junkyards, anyone know exactly what those 3 ft shafts came on? car-part doesn't really list them, and the junkyards are retarded about helping me find one (they think there is only halfshaft setups...)

rusty
07-16-2011, 05:17 AM
the 1.9L escorts didn't use the split shaft, full length from trans to RF wheel. I am not sure how it will line up at the trans but hub fitment should be fine.

bloodyspirit058
07-16-2011, 08:02 PM
the 1.9L escorts didn't use the split shaft, full length from trans to RF wheel. I am not sure how it will line up at the trans but hub fitment should be fine.

was waiting for this kinda info, local jy had tons of them for like 30 bucks, picked one up and it fit perfect so far, car isn't running yet, but everything fits, not sure if it will leak, but if it does, it probably did before :P

bloodyspirit058
07-17-2011, 06:59 PM
kia injectors = 230 cc/min


needed to right this down some where, took a while, but found the info on a miata site, wish i could confirm it, oh well

bloodyspirit058
02-16-2015, 10:06 PM
So... can't believe its been almost 4 years... tried selling the car a couple times, but just couldn't let it go. swapped it all back to the 1.5 and stock cpu, was still having issues. Brought it to a local "mechanic" and a bad stock cpu and distributor were the issue. After hearing this i couldn't believe my whole swap project was brought down by a distributor, seems like something i would have figured out especially after having one go on my old 96 dx...

For the time being the car has returned to gas saving commuter.

farcryNZ
07-01-2016, 06:14 PM
Hey man, any updates with this beast?
I have been dreaming of going down the same process, starting all my mods with a mega squirt.
Only I can't find naff all wiring diagrams or info to allow me to know what I'm doing before I do it haha, but that's my problem. How's your car going?


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