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    1st Gens 1990 4WD work log

    I'll try to keep this updated. It's really just going to be a bunch of pics. I'll link any work logs I have back here when it comes time to tie everything together.
    What a storm outside. I went out to take some more pics and the wind just roared through the trees.

    Edit-March 23, 2013. I hope people are able to find something in this log they can use. In no way am I saying this is what you should do. All I'm saying with this log is, this is what I did. These are the questions I faced and the answers I came up with. Thank you to the people that participated in problems solving. I could not have done it without you.



    Unfortunately for my work log, we now have advertisement links in most of the posts. The links I posted are among them so you're just going to have to sift through the BS. Sucks I know.

    Resized pics brought to you by Fotosizer. This program is WAY easier to use than Gimp or PS.

    Work log from previous owner
    And the owner before that
    Reference gallery and info on 4WD Chassis
    A link on FEOA for good pics
    SgtRauksauff's 4WD Work Log with some great projects.

    Some Torque Specs
    Might be easier to read specs
    Rear Suspension Torque Specs
    A thread about suspension upgrades

    1990 Protege 4WD
    BPT engine (BP26)with new
    timing belt with idlers and tensioner
    water pump
    plugs and wires
    disty
    O2 Sensor
    alternator and belts
    rear main seal

    Spal slim fan (not new)
    BP harness with 3 to 4 wire TPS mod
    GTX ECU
    BP 22 Throttle body out of an EGT with an ATX
    SMIC from GT-X with all the piping (has now been upgraded to FMIC, see links at bottom of page)
    vj20/vf8 hybrid



    BPT 4WD tranny with BP Flywheel
    new Spec 2+ clutch kit

    GTR Viscous LSD (I haven't installed this yet for some reason)
    Great pics of the rear diff assembly out of the car
    seals

    New
    pilot bearing
    lower ball joints
    Brembo plain rotors in front, brand X in back
    calipers in front and back
    ceramic pads front and back
    front brake lines
    Front sway bar bushings and end links.
    both front wheel bearings
    both front axles
    Pinion arm boots
    All new hoses, belts, and fluids
    clutch master cylinder
    Power steering pump delete. Drained the rack and looped the lines.

    Edit- If you have work to do to the steering rack, make sure you do it BEFORE you put the engine in. What a PITA!

    Edit 2.0-

    vj20/vf8 hybrid turbo upgade Purchase thread
    Pics of work done with additional links, FMIC install, injectors
    Pics of VJ20 installed and VJ20/VF8 hybrid
    Innovate MTX-L Wideband install and novice tuning
    Evo 8 ECU, harness, and individual coil pack, upgrade on B4pro
    Attached Files
    Last edited by DuRWooD; 07-31-2016, 05:47 PM.
    1991 Protege LX with GTX swap, DD
    1990 4WD Protege with GTX swap, Project/garage decoration
    2006 Mazda 3 with 2.3, Her car
    1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

    #2
    The wheel bearing. Mike at the machine shop helped me to liberate the axle shaft then reinstall the bearing. I probably didn't need the bearing but something tells me it was a good idea.
    Is something up with that tie rod being all crooked like that?
    Edit-Ask a stupid question and, well. The tie rod looks like that because the car is up on blocks.
    Attached Files
    Last edited by 1st Gen; 07-21-2010, 06:29 AM.
    1991 Protege LX with GTX swap, DD
    1990 4WD Protege with GTX swap, Project/garage decoration
    2006 Mazda 3 with 2.3, Her car
    1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

    Comment


      #3
      Need new studs for the output shaft. The other work foobar pretty bad.
      The VLSD Thread
      Attached Files
      Last edited by 1st Gen; 03-29-2010, 02:07 PM.
      1991 Protege LX with GTX swap, DD
      1990 4WD Protege with GTX swap, Project/garage decoration
      2006 Mazda 3 with 2.3, Her car
      1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

      Comment


        #4
        The ECU under the belts is the BP 26
        The tranny with the red cap in the output shaft hole is the GTX.
        The Transmission thread
        The Throttle Body Thread
        The Clutch Thread
        Attached Files
        Last edited by 1st Gen; 08-24-2010, 02:48 PM.
        1991 Protege LX with GTX swap, DD
        1990 4WD Protege with GTX swap, Project/garage decoration
        2006 Mazda 3 with 2.3, Her car
        1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

        Comment


          #5
          My BPT thread

          Got around today and changed some things. New,
          water pump
          idler and tentioner
          timing belt
          plugs and wires
          ditsy

          Also took accessory brackets off other BP to install power steering pump and alternator.
          Removed plugs stubs and hoses from the motor that were just cut off for the extraction.
          Put on the new throttle body with the 4 wire TPS,
          3 to 4 wire TPS conversion thread
          I'm going to use the How to on the FEOA site. I won't know if it works really until I go to fire it up.
          More good harness information
          VAF plug discussion



          Note-you can pick up a scalpel at most hobby shops or art stores and they work great for trimming a harness.
          Attached Files
          Last edited by 1st Gen; 09-03-2010, 01:05 AM.
          1991 Protege LX with GTX swap, DD
          1990 4WD Protege with GTX swap, Project/garage decoration
          2006 Mazda 3 with 2.3, Her car
          1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

          Comment


            #6
            Update,
            My goal is to have this car in my garage by the time the weather changes. It's not going to sit out for another year. To do that, I need to
            Get engine in and running and get brakes working.

            If I get it running and inside garage, I can work on it all winter and have it ready for business by next summer. That's the plan anyway. I'm also pulling together some resources to be able to paint. Even if it's only primer, at least I'll be able to do some proper body work and take care of some rust issues. There is some rust but not much at all. A little on the trunk deck which is easily fixed and some on a few parts and that's it. (Whew!)

            My j/y list is as follows
            head liner,
            radio antenna,
            Trunk deck
            antenna
            Drivers side mirror
            clips, screws, plugs, bolts
            Moister barrier for DS door


            slim Fan
            This is coming from a fellow member on the boards here.
            Brembo front rotors
            Got this from Costless



            Installed new coolant hoses to and from turbo



            Check SMIC for fitment and completeness

            Get BP on the stand, get the pan and dampener off and see if I can free it up again.
            buy 1/4" extension



            Price getting 220V installed to the shop for welder/compressor fun.
            Last edited by 1st Gen; 09-03-2010, 01:25 AM.
            1991 Protege LX with GTX swap, DD
            1990 4WD Protege with GTX swap, Project/garage decoration
            2006 Mazda 3 with 2.3, Her car
            1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

            Comment


              #7
              The Interior work
              Attached Files
              Last edited by 1st Gen; 07-25-2010, 02:35 PM.
              1991 Protege LX with GTX swap, DD
              1990 4WD Protege with GTX swap, Project/garage decoration
              2006 Mazda 3 with 2.3, Her car
              1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

              Comment


                #8
                The cross member bracket went from a question mark to a period today. I had to fashion a rubber grommet out of a compression plug since one hole is bigger and I'm missing the one that came with the car originally. I'm pleased with the outcome.

                I also chased some threads with a 12x1.25 die.
                Attached Files
                Last edited by 1st Gen; 09-02-2010, 12:39 AM.
                1991 Protege LX with GTX swap, DD
                1990 4WD Protege with GTX swap, Project/garage decoration
                2006 Mazda 3 with 2.3, Her car
                1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

                Comment


                  #9
                  very nice! i'm jealous of the awd clean car though. looking forward to seeing the rest of it
                  -Jack

                  ONTARIO MAZDA CLUB! Join! https://www.facebook.com/groups/500055016671733/

                  91 626 LX - basically stock and pretty slow still
                  http://www.clubprotege.com/forum/sho...my-GD-626-LX-)

                  01 E53 3.0i - FOR SALE! pm if interested

                  91 USDM Protege LX - SOLD! turbo/manifold up for sale!
                  http://www.clubprotege.com/forum/showthread.php?t=46606

                  Comment


                    #10
                    nice. subbin'
                    -Steve

                    94' Protege < Worklog<SOLD!
                    VF10 powered!
                    262 Whp & 257 Wtq
                    13.1@107

                    '02 Suzuki Bandit 600s

                    Comment


                      #11
                      Nice pics
                      Cincinnati, ohio Bengals for life
                      "Who Dey"

                      Comment


                        #12
                        Still need to buy
                        nuts for the bolts I have for the differential
                        temp sensor
                        both tie rod ends (they both look dry as a bone)
                        fluids for engine, tranny, power steering, brakes
                        brake grease
                        muffler
                        high flow cat
                        2.5" straight pipe
                        boost gauge
                        rubber hoses and clamps for SMIC
                        Headlight bulb


                        Walbro fuel pump
                        This is on the way, Kit FPM 002 from the application page. I called the guy and this is what he recommended to me. I've dealt with him before and I recommend him as a nice guy to deal with.


                        Battery
                        Work on brakes and try to get those working or find out why they won't work

                        Tools to buy
                        Sawzall, either from the used tool shop down the street or a cheap model from one of the big box stores
                        Welder from Hobart tools. I know it's cheap but it only has to perform for less than 10 hours. If I could justify an expensive model I would buy one, believe me.


                        Hook up chassis harness front of core support. There's a lot going on there with plugs not accounted for. I think I'll see a lot more when I get the bumper off.
                        Torque lower ball joints properly. Right now they're just tight.
                        Get SMIC fitted and decide on mounting solution
                        figure out the easiest way to bleed all the hydraulic systems so I don't waste a ton of fluid. I think I'll need a helper with this.
                        As it turns out, the power steering pump for a GTX is different than that for a B8. Stands to reason I guess. I just wish I had looked at it before now. I have the other pump. I just need to swap them. Bother.


                        The tires I'm going to use. Yesss, I have the whole set.
                        Attached Files
                        Last edited by 1st Gen; 04-22-2011, 04:31 PM.
                        1991 Protege LX with GTX swap, DD
                        1990 4WD Protege with GTX swap, Project/garage decoration
                        2006 Mazda 3 with 2.3, Her car
                        1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

                        Comment


                          #13
                          The Exhaust Build

                          I got to working on the RF suspension swapping out some parts and noticed the hub is loose. Yea this is the same one I replaced the bearing in. I got to looking at it and it looks like the bearing is actually moving a bit inside the spindle. I was pretty down about this for a while but then went and checked the other side and found it to be the same way. Hmm.

                          I guess I'll just roll with it and hope it's nothing out of the ordinary. I would not have thought there would be any slack there though. This is without the axles in.

                          The Axle thread
                          Last edited by 1st Gen; 10-01-2010, 12:28 AM.
                          1991 Protege LX with GTX swap, DD
                          1990 4WD Protege with GTX swap, Project/garage decoration
                          2006 Mazda 3 with 2.3, Her car
                          1980 Ford F100 Short bed with 300ci 6 cylinder, work truck/home for moss

                          Comment


                            #14
                            you'll have some slop w/o the axles, because as far as I know, the axle nut torque is what keeps the bearing together properly. Hence the problems when someone forgets to tighten the axle nut, and the wheel bearing dies an ignominious death shortly thereafter.


                            --sarge

                            Comment


                              #15
                              ^^ yes exactly.. Thats also why you DO NOT roll cars without the axles in... if you dont have a brake set up on there so the rotor can rest on the caliper the wheels WILL fall off..

                              1992 MX-3 GS - KLZE
                              1997 Probe GT

                              Its not a BP05.... Its a BPOS... BIG PIECE OF ****

                              Comment

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