Speeder

I think you could say this is a very bad thing.

Was taking down the ride tonight for the new engine installation. Saw a puddle of water in the exhaust manifold. Figured it was from taking the turbos off. Wrong!

Might explain the no revs past 5K , no power & **** poor running in general. As a sidenote, saw the turbo manifold too. One hairline crack & that was it. The things had a reman tag on `em I missed from an earlier observation. They had a little oil in them but wasnt`t much! May just put them back on after I am finished with the engine install.

Oh boy.......

Speeder

Figured out also where the underhood smoke was coming from as well. A coolant hose was leaking & spraying water down the side of the block & onto the exhaust manifold. Glad I found it now as it was pretty swollen & looked to me to be ready to burst. The more I get into this thing, the more I am finding things to repair. Planning on doing a complete vacuum hose replacement too. Think it would be worth it at this stage.

Signal 2

The first picture suggests a coolant seal failure. But that doesn't mean the block isn't rebuildable.



It's pretty common for the upper turbo coolant line to fail like that over time from all the heat....though yours looks alot worse than mine did at 85k. Good thing your rebuilding...coolant will burn if you get it hot enough.

Speeder

"It's pretty common for the upper turbo coolant line to fail like that over time from all the heat....though yours looks alot worse than mine did at 85k. Good thing your rebuilding...coolant will burn if you get it hot enough."







Well, I have around 112K miles on the engine so I definitely went longer than you did. Glad I saw the hose now because I sure would have hated to have gotten out somewhere far away from home & "Pop"!!! DOH!!!! Gotta hate that!

Went by the Mazda dealership a couple days ago to order replacement gaskets for some of the critical areas that will need them. The guy I deal with there, cut me a heck of a deal on the parts & it still went over 300 bucks. Got a funny feeling that it won`t stop there.

Well, time to get off of my can & go back out in the garage & pull some more things off the motor. Was kinda hoping that maybe those difficult to remove accessories would just jump right off the motor by themselves while I sit in the house surfing the web but I checked a little while ago & the car still looks the same as when I left it a few days ago.....

Signal 2

I understand you have a guy at a local dealership...and that's good. But if you can show results from a sanctioned event or two NASA or SCCA (like autocross), you won't find better prices and technical help than here for your rebuild... http://www.mazdamotorsports.com/webapp/wcs...catalogId=10001 . Probably saved me $600 to $800 on my rebuild a year and a half ago.

If not, many use MALLOY MAZDA for alot of OEM parts http://mazda.malloyautomall.com/Department-Parts.aspx. Even with shipping (which is quick), they're usually cheaper than I can get stuff anywhere else but MAZDAMOTORSPORTS...even if ordered through a family owned business. Ask for Ray Crowe, he's an FD owner himself.

Good luck.

Speeder

Someone else the other day told me the same thing about being in a sanctioned event or two. I have had one fellow in town try to get me to go to an event awhile back. I almost did but got sidetracked. I guess it is a little late in the game now to get the "discount" on parts but I am seriously thinking of trying an event in the near future. Looks like my friend charged me around 15% over cost for the parts I have bought as of two days ago. I have no complaints really but who wants to have to pay any more than they have too?

Excellent advice though Jim & thank you for it!



As soon as I get my car back on the road I wouldn`t mind at all of entering it in an event or two to get my feet wet. I really think it would be fun.





Time for some chow & then off to bed. Bending over that engine compartment for long periods of time for a guy over 40 is not as easy to do as when I was younger! LOL! The parts are STILL coming off! I am wondering how they were able to fit all of those things in there!!! Man! I am gonna hate putting all of those valves & hoses back on the new motor! This has got to be one of the biggest undertakings of my entire meager existence!



As a side note I would like to add here, I told the guy down at the Mazda parts department the other day about this undertaking of mine. He said if I could do this project, all of the other Mazda cars they see every day for service would be EASY!! Eek!!! Ummmmm...wonder if he knows something I don`t?!!

Signal 2

It's not that bad. Just stick with the FSM.

Some advice from personal experience.......

*Hopefully you have a dedicated space.....keep it well lit, and very clean.

*Pretty daunting early on when you first start out. Try to do something on it every day or two, even when your just waiting for parts. Cleaning parts, cleaning the engine bay, re-wrappng what will likely be a crispy engine harness etc. I found doing that kept me focused and motivated over the long haul.

*If you have the room and don't already have compressed air, consider buying a small compressor.

*If this is your first time, keep a camera handy and take digital photographs as you disassemble for possible later reference. Different angles, distances etc. Especially of areas like the "rats nest" solenoid rack. You may never need them, but......



BTW, I've probably got 10+ yrs on you. This is a job even the elderly can do.

Good luck and post up your progress when you can.

Speeder

"It's not that bad. Just stick with the FSM."



I have the thing opened now laying on the front of the car. I am trying real hard to not get oil & fingerprints all over it!



I live by myself so have the garage all to myself as well. I am glad because I can put things wherever I want & not have to worry about them "wandering about" while I am not around. I have a 60 gallon upright air compressor which does get its fair share of use. I like having air capability especially when needing an air wratchet to loosen bolts with or need of an impact wrench to break those stubborn bolts free. Used to work in car audio years ago & figured out quickly that air tools were wonderful!



Know what you mean about the crispy engine harness. There are definitely places that need to be rewrapped. I think I will do that. Amazing what that engine heat can do to them.



+1 on the photos too. I am taking lots of them. I like that little bit of additional "peace of mind" factor. Speaking of mind, I don`t remember things as well as I used too.



Trying to stay motivated on this project. I think the thing that keeps me going the most is the joy I had of driving it & how much fun it was. A second reason is, I don`t want to have the thing towed to a shop & tell them to finish the installation for me! I could just see the bill on that one IF...& I say IF they would even fool with it!



More to come.

Signal 2

You can download the FSM from a few different sources for free. Then print the pertinent pages to take to the garage and save the hard copy book for study timel.

I like silicone self-fusing tape...sometimes called fusion tape. Sticks to itself and no adhesive. Available under various brands or through McMaster-Carr. I get mine at the local MENARD'S under the GB brand. A little pricey, but it stands up to the underhood temps and won't dry out like electrical tape and water resistant. It also stretches and goes farther than you think.

Speeder

"I like silicone self-fusing tape...sometimes called fusion tape. Sticks to itself and no adhesive. Available under various brands or through McMaster-Carr. I get mine at the local MENARD'S under the GB brand. A little pricey, but it stands up to the underhood temps and won't dry out like electrical tape and water resistant. It also stretches and goes farther than you think."



I will look into that Jim! Thank you! I have a McMaster - Carr catalog here. About time for bed so think I may do a little "reading" in that catalog before I turn in. Got a call from Mazda today. Parts are in. Tomorrow, road trip!